Universal sloped roof solar panel mounting system

ABSTRACT

A universal mounting system for supporting a plurality of photovoltaic modules on a sloped support surface, such as a sloped roof, is disclosed herein. The universal mounting system may include one or more support surface attachment devices, each support surface attachment device configured to attach one or more photovoltaic modules to a support surface; and one or more module coupling devices, each module coupling device configured to couple a plurality of photovoltaic modules to one another.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to U.S. Provisional ApplicationNo. 62/556,486, entitled “Universal Sloped Roof Solar Panel MountingSystem”, filed on Sep. 10, 2017; and is a continuation-in-part of U.S.Nonprovisional patent application Ser. No. 15/387,481, entitled “SlopedRoof Solar Panel Mounting System”, filed on Dec. 21, 2016; and U.S.Nonprovisional patent application Ser. No. 15/387,481 is acontinuation-in-part of U.S. Nonprovisional patent application Ser. No.15/068,370, entitled “Sloped Roof Solar Panel Mounting System”, filed onMar. 11, 2016, which claims priority to U.S. Provisional PatentApplication No. 62/131,743, entitled “Sloped Roof Solar Panel MountingSystem”, filed on Mar. 11, 2015, and to U.S. Provisional PatentApplication No. 62/192,529, entitled “Sloped Roof Solar Panel MountingSystem”, filed on Jul. 14, 2015, the disclosure of each of which ishereby incorporated by reference as if set forth in their entiretyherein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK

Not Applicable.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The field of the present invention generally relates to mounting systemsand, more particularly, to support assemblies and mounting systems formounting photovoltaic modules or panels on sloped support surfaces suchas, for example, sloped building rooftops, or the like.

2. Background

There is a need for a sloped roof solar panel mounting system thatattaches to rafters or roof supporting members, avoids using rails orstruts, and is universal.

Solar panels must be secured to the roof and underlying structure todisperse wind and snow loads into the building structure. Although somemounting systems that avoid using rails attach to the roof decking, theydo not attach to the roof rafters because the spacing of rafters isdifferent than the length of modules.

Rails and struts are long extrusions or roll-formed strips that must becut to length, use excess material, are costly to manufacture and highin shipping cost. Therefore, a mounting system avoiding the use of railsor struts is desired.

There is a need for the system to mount to any solar module on themarket, giving installers the flexibility to choose the module of theirchoice, rather than be required to buy a module with a custom profilerail to accommodate the mounting system. Also, there is a need for amounting system that utilizes a universal skirt for all common solarmodule thicknesses.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

Accordingly, the present invention is directed to a universal slopedroof solar panel mounting system that substantially obviates one or moreproblems resulting from the limitations and deficiencies of the relatedart.

In accordance with one or more embodiments of the present invention,there is provided a support surface attachment device, the supportsurface attachment device configured to attach one or more photovoltaicmodules to a support surface. The support surface attachment deviceincludes a base assembly configured to be attached to a support surface;and a clamp assembly configured to engage one or more photovoltaicmodules, the clamp assembly including a lower clamp member and an upperclamp member, the upper clamp member connected to the lower clamp memberby a fastener member, the lower clamp member including one or more firstteeth disposed thereon, and the upper clamp member including one or moresecond teeth disposed thereon, the one or more first teeth on the lowerclamp member configured to engage the one or more second teeth on theupper clamp member when the fastener is being tightened so as tomaintain a minimum gap between the upper clamp member and the lowerclamp member for receiving one or more photovoltaic module frames of theone or more photovoltaic modules when the one or more photovoltaicmodules are pivotably installed into a first side of the clamp assembly.The clamp assembly is capable of being selectively positioned along alength of the base assembly prior to being fixed in place relative tothe base assembly so as to permit adjustability when the one or morephotovoltaic modules are being attached to the support surface.

In a further embodiment of the present invention, the upper clamp memberof the clamp assembly comprises one or more grooves for receiving aportion of a bonding clip for grounding the one or more photovoltaicmodules.

In yet a further embodiment, the support surface attachment devicefurther comprises a spring member disposed between the upper clampmember and the lower clamp member of the clamp assembly, the springmember configured to hold the clamp assembly open for facilitating theinstallation of the one or more photovoltaic modules into the clampassembly, and the spring member further configured to enable the clampassembly to be secured on the base assembly while maintaining theminimum gap between the upper clamp member and the lower clamp member.

In still a further embodiment, the support surface attachment devicefurther comprises a strut nut threadingly coupled to the fastenermember, the strut nut configured to fix the clamp assembly in placerelative to the base assembly when the fastener member is tightened.

In yet a further embodiment, the fastener member comprises a visualindicator line formed on a head portion of the fastener member forindicating an orientation of the strut nut.

In still a further embodiment, the support surface attachment devicefurther comprises a glider member coupling the upper and lower clampmembers of the clamp assembly to the base assembly, the glider memberconfigured to slide relative to the base assembly so as to allow theclamp assembly to be selectively positioned along the length of the baseassembly prior to being fixed in place relative to the base assembly.

In yet a further embodiment, the glider member comprises one or moreprotrusions or grooves formed in an outer side of the glider member, theone or more protrusions or grooves configured to serve as a visualindicator indicating a height of the clamp assembly relative to the baseassembly and/or serve as a means for holding a chalk line during aninstallation of the one or more photovoltaic modules.

In yet a further embodiment, the upper and lower clamp members of theclamp assembly are configured to rotate together relative to the glidermember, and wherein an upstanding base member of the base assembly isconfigured to rotate relative to the support surface, whereby therotation of the upper and lower clamp members relative to the glidermember and the rotation of the upstanding base member of the baseassembly relative to a flashing member of the support surface attachmentdevice enables a lateral position of the clamp assembly to be adjustedby an installer.

In still a further embodiment, the lower clamp member of the clampassembly comprises one or more ridges disposed on a bottom surface ofthe lower clamp member, the one or more ridges configured to increase africtional engagement between the lower clamp member and the glidermember so as resist the upper and lower clamp members of the clampassembly from rotating relative to the glider member when the fastenermember is tightened by an installer.

In yet a further embodiment, base assembly includes an upstanding basemember, the upstanding base member comprising one or more mating groovesand one or more mating protrusions for engaging with one or more matingprotrusions and one or more mating grooves of the glider member, whereina selected engagement between the one or more mating grooves andprotrusions of the upstanding base member and the one or more matinggrooves and protrusions of the glider member enables the clamp assemblyto be selectively positioned at a predetermined height relative to thebase assembly prior to being fixed in place relative to the baseassembly so as to permit vertical adjustability when the one or morephotovoltaic modules are being attached to the support surface.

In still a further embodiment, the upper clamp member of the clampassembly comprises a first downwardly protruding member and a seconddownwardly protruding member spaced apart from the first downwardlyprotruding member by a gap, the second downwardly protruding memberbeing shorter in length than the first downwardly protruding member, andthe second downwardly protruding member configured to provide anabutment surface for a skirt member.

In yet a further embodiment, the lower clamp member of the clampassembly comprises one or more mating grooves and one or more matingprotrusions for engaging with one or more mating protrusions and one ormore mating grooves of a skirt member.

In still a further embodiment, the one or more mating protrusions on thelower clamp member are upwardly inclined so as to enable the skirtmember to be inserted into the clamp assembly from above duringinstallation, and so as to prevent the skirt member from becomingdisengaged from the clamp assembly after the installation of the skirtmember.

In yet a further embodiment, the upper clamp member of the clampassembly comprises a pair of downwardly extending lip portions onopposite sides of a top portion of the upper clamp member, a first oneof the pair of downwardly extending lip portions being longer than asecond one of the pair of downwardly extending lip portions so as tofacilitate the one or more photovoltaic modules being pivotablyinstalled into the first side of the clamp assembly.

In still a further embodiment, the lower clamp member of the clampassembly comprises an upwardly tapered ledge extending outwardly fromthe first side of the clamp assembly, the upwardly tapered ledgeconfigured to support the one or more photovoltaic module frames of theone or more photovoltaic modules, and the upwardly tapered ledge beingconfigured to function as a spring for applying a compressive forceagainst the one or more photovoltaic module frames of the one or morephotovoltaic modules so as to securely retain the one or morephotovoltaic modules in the clamp assembly after the one or morephotovoltaic modules are pivotably installed.

In yet a further embodiment, the base assembly includes an upstandingbase member, the upstanding base member including a pair of verticallyspaced-apart bottom wall portions, a first of the pair of verticallyspaced-apart bottom wall portions comprising a first aperture and asecond of the pair of vertically spaced-apart bottom wall portionscomprising a second aperture, the first and second apertures of theupstanding base member configured to receive a raised portion of aflashing member therein so as to permit a fastener aperture disposed inthe flashing member to be elevated above the support surface, therebyenabling the support surface attachment device to be more leakageresistant.

In yet a further embodiment, the upstanding base member of the baseassembly further comprises one or more base flange portions, the one ormore base flange portions having one or more mounting apertures disposedtherethrough, the one or more mounting apertures configured to receiveone or more respective fasteners for securing the upstanding base memberto the support surface.

In still a further embodiment, a bottom surface of the upstanding basemember comprises one or more ridges disposed thereon, the one or moreridges configured to increase a frictional engagement between theupstanding base member and the flashing member so as prevent theupstanding base member from rotating relative to the flashing memberwhen a base fastener member is tightened by an installer.

In yet a further embodiment, the one or more ridges disposed on thebottom surface of the upstanding base member are additionally configuredto capture and hold sealing tape when the upstanding base member ismounted directly against the support surface.

In still a further embodiment, a top surface of the upstanding basemember comprises one or more visual installation guide marks configuredto facilitate an installation of one or more rows of the one or morephotovoltaic modules.

In yet a further embodiment, the support surface attachment devicefurther comprises a flashing member having a fastener apertureconfigured to receive a base fastener member for attaching an upstandingbase member of the base assembly and the flashing member to the supportsurface, the fastener aperture being disposed through a raised positionof the flashing member so that water is prevented from passing throughthe fastener aperture.

In yet a further embodiment, the support surface attachment devicefurther comprises a sealing washer configured to be disposed between ahead of the base fastener member and a top rim of the raised position ofthe flashing member, the sealing washer including an upper portionformed from a first material and a lower portion formed from a secondmaterial, the first material forming the upper portion of the sealingwasher restricting a deformation of the second material forming thelower portion of the sealing washer so as to prevent the sealing washerfrom entering the fastener aperture in the flashing member.

In still a further embodiment, the lower portion of the sealing washerfurther comprises a tapered bottom surface so as to tightly engage thetop rim of the raised portion of the flashing member and to prevent thesecond material forming the lower portion of the sealing washer fromentering the fastener aperture in the flashing member.

In yet a further embodiment, the raised portion of the flashing membercomprises a circumferential ledge portion, wherein, when the upstandingbase member of the base assembly is assembled with the flashing member,a top surface of the circumferential ledge portion of the raised portionof the flashing member is configured to regulate a height of an uppersection of the raised portion of the flashing member that is disposedabove the circumferential ledge portion so that a top rim of the uppersection of the raised portion does not protrude substantially above atop surface of an elevated shelf of the upstanding base member.

In still a further embodiment, the support surface attachment devicefurther comprises a cantilevered mounting arm coupling the clampassembly to the base assembly, the cantilevered mounting arm configuredto support the clamp assembly in a cantilevered manner from the baseassembly so that the clamp assembly is capable of being horizontallyoffset from the base assembly, thereby allowing one or more edges of theone or more photovoltaic modules to be disposed above a region of thesupport surface that is unable to accommodate the base assembly.

In yet a further embodiment, the region of the support surface that isunable to accommodate the base assembly comprises an area at or near aroof ridge, and wherein the cantilevered mounting arm enables one ormore additional photovoltaic modules to be installed proximate to theroof ridge.

In still a further embodiment, the support surface attachment devicefurther comprises an electrical accessory bracket configured to mount anelectrical accessory of a photovoltaic system to an upstanding basemember of the base assembly, the electrical accessory bracket comprisingat least one flange portion configured to attach the electricalaccessory bracket to the upstanding base member, the electricalaccessory bracket further comprising a bracket base portion comprisingone or more mounting apertures for attaching the electrical accessory tothe electrical accessory bracket.

In yet a further embodiment, the at least one flange portion of theelectrical accessory bracket is offset from a center position of thebracket base portion in a widthwise direction of the bracket baseportion so as to facilitate a connection of one or more wires to theelectrical accessory without the upstanding base member of the baseassembly interfering with a routing of the one or more wires.

In still a further embodiment, the bracket base portion of theelectrical accessory bracket comprises a plurality of slots formedtherein for accommodating various electrical accessories, and whereinthe at least one flange portion of the electrical accessory bracketcomprises at least one aperture formed therein for accommodating agrounding lug.

In yet a further embodiment, the support surface attachment devicefurther comprises a conduit mounting member configured to mountelectrical conduit of a photovoltaic system to an upstanding base memberof the base assembly, the conduit mounting member including a securementportion comprising one or more mounting apertures for attaching theconduit mounting member to the upstanding base member, the conduitmounting member further comprising a conduit mounting portion connectedto the securement portion, the conduit mounting portion comprising oneor more securement apertures for attaching the electrical conduit to theconduit mounting member.

In accordance with one or more other embodiments of the presentinvention, there is provided a coupling device configured to attach oneor more photovoltaic modules to one or more other photovoltaic modules.The coupling device includes a lower coupling member including at leastone ledge extending outwardly from a side surface of the lower couplingmember, the lower coupling member further including one or more firstteeth disposed thereon; and an upper coupling member including at leastone flange portion extending outwardly from the upper coupling member,the upper coupling member further including one or more second teethdisposed thereon, the upper coupling member being adjustably connectedto the lower coupling member by at least one fastening device, the oneor more first teeth on the lower coupling member configured to engagethe one or more second teeth on the lower coupling member when the atleast one fastening device is being tightened so as to maintain aminimum gap between the upper coupling member and the lower couplingmember for receiving one or more photovoltaic module frames of the oneor more photovoltaic modules when the one or more photovoltaic modulesare pivotably installed into a first side of the clamp assembly. The oneor more other photovoltaic modules are configured to be clamped betweenthe at least one ledge of the lower coupling member and the at least oneflange portion of the upper coupling member.

In a further embodiment of the present invention, the at least oneflange portion of the upper coupling member comprises a plurality ofspaced-apart apertures disposed therethrough, and wherein the at leastone fastening device comprises a first and second fastening device, afirst one of the plurality of spaced-apart apertures comprising afastener hole for receiving the first fastening device, and the secondone of the plurality of spaced-apart apertures comprising a fastenerslot for receiving the second fastening device, the fastener slotproviding clearance so as to allow the tightening of one of the firstand second fastening devices prior to the tightening of the other of thefirst and second fastening devices.

In yet a further embodiment, the at least one flange portion of theupper coupling member comprises a central slot disposed between thefirst one of the plurality of spaced-apart apertures and the second oneof the plurality of spaced-apart apertures, the central slot configuredto receive a fastener member for connecting the coupling device to aglider member of a support surface attachment device so that thecoupling device is capable of being used with a base assembly of thesupport surface attachment device for attaching the one or morephotovoltaic modules to a support surface.

In still a further embodiment, a top surface of the at least one flangeportion of the upper coupling member comprises one or more visualinstallation guide marks to indicate locational limits of mounting theone or more photovoltaic modules within the coupling device.

In yet a further embodiment, the lower coupling member comprises one ormore mating grooves and one or more mating protrusions for engaging withone or more mating protrusions and one or more mating grooves of a skirtmember.

In still a further embodiment, the one or more mating protrusions of thelower coupling member comprise a plurality of mating protrusionsdisposed in alternating upward and downward orientations so that thecoupling device is capable of remaining in engagement with the skirtmember prior to the at least one fastening device being tightened by aninstaller.

In yet a further embodiment, the lower coupling member comprises one ormore water drainage troughs formed therein for draining water from theone or more photovoltaic modules.

In accordance with yet one or more other embodiments of the presentinvention, there is provided a bonding clip configured to ground one ormore photovoltaic modules. The bonding clip includes a clip body portionhaving a first surface and a second surface disposed opposite to thefirst surface, the clip body portion further including a plurality ofprotruding members, at least one of the plurality of protruding membersprojecting outwardly from the first surface in a first direction, and atleast another of the plurality of protruding members projectingoutwardly from the second surface in a second direction, the firstdirection being generally opposite to the second direction; and one ormore clip attachment portions connected to the clip body portion, theone or more clip attachment portions configured to attach the bondingclip to an object on which the bonding clip is mounted.

In a further embodiment of the present invention, the plurality ofprotruding members are arranged in a generally staggered pattern along alength of the clip body portion.

In yet a further embodiment, the clip body portion is in the form offlat plate that does not comprise any folds formed therein.

In still a further embodiment, the one or more clip attachment portionscomprise a plurality of bent tab members, the plurality of bent tabmembers configured to engage with a groove in the object.

In yet a further embodiment, the one or more clip attachment portionscomprise a pair of flange members, each of the pair of flange membersbeing disposed at an opposite end of the clip body portion; and wherein,when the bonding clip is installed on the object, a top portion of eachof the pair of flange members remains visible to an installer so that aninstalled condition of the bonding clip is capable of being verified bythe installer.

In accordance with still one or more other embodiments of the presentinvention, there is provided a power accessory bracket configured toattach one or more power accessories of a photovoltaic system to one ormore frames of one or more photovoltaic modules. The power accessorybracket includes a bracket body portion having a first side and a secondside disposed opposite to the first surface; a first plurality of teethdisposed on the first side of the bracket body portion, the firstplurality of teeth configured to engage the one or more frames of theone or more photovoltaic modules; and a second plurality of teethdisposed on the second side of the bracket body portion, the secondplurality of teeth configured to engage one or more mounting members ofthe one or more power accessories. The power accessory bracket isconfigured to provide electrical bonding of the one or more photovoltaicmodules to the one or more power accessories.

In a further embodiment of the present invention, at least one of thefirst and second pluralities of teeth extend below a bottom surface ofthe bracket body portion so as to provide the electrical bonding and toaccommodate a plurality of different photovoltaic module flangedimensions.

In yet a further embodiment, the bracket body portion comprises at leastone mounting aperture disposed therethrough, the at least one mountingaperture being offset from a center position of the bracket body portionin a widthwise direction of the bracket body portion so as toaccommodate a plurality of different photovoltaic module flangedimensions by allowing the power accessory bracket to positioned in twodifferent orientations.

In still a further embodiment, the bracket body portion comprises atleast one additional aperture formed therein for accommodating one ormore components of one or more power accessories.

In accordance with still one or more other embodiments of the presentinvention, there is provided a support surface attachment device, thesupport surface attachment device configured to attach one or morephotovoltaic modules to a support surface. The support surfaceattachment device includes a base assembly configured to be attached toa support surface; and a clamp assembly configured to engage one or morephotovoltaic modules, the clamp assembly including a lower clamp memberand an upper clamp member, the upper clamp member being adjustablyconnected to the lower clamp member by a fastener member, the upper andlower clamp members defining a panel receiving gap therebetween, thepanel receiving gap being continuously adjustable by a user within therange between approximately 32 millimeters and approximately 50millimeters so as to accommodate any photovoltaic module thicknesswithin the range.

In a further embodiment of the present invention, the clamp assemblycomprises integrated grounding means, the integrated grounding meansconfigured to provide integrated grounding between adjacent photovoltaicmodules.

In yet a further embodiment, the integrated grounding means of the clampassembly comprises one or more grounding protrusions or teeth.

In still a further embodiment, the upper clamp member of the clampassembly comprises at least one downwardly extending portion and thelower clamp member of the clamp assembly comprises at least one upwardlyextending portion, the at least one downwardly extending portion of theupper clamp member configured to engage with the at least one upwardlyextending portion of the lower clamp member so as to hold open the panelreceiving gap for facilitating an insertion of the one or morephotovoltaic modules after the fastener member of the clamp assembly hasbeen partially tightened.

In yet a further embodiment, the at least one upwardly extending portionof the lower clamp member comprises one or more outwardly extendingprotrusions, the one or more outwardly extending protrusions configuredto facilitate the holding open of the panel receiving gap, the one ormore outwardly extending protrusions further configured to be deformedand/or severed from the remainder of the upwardly extending portion ofthe lower clamp member when the fastener member of the clamp assembly istightened.

In still a further embodiment, the at least one downwardly extendingportion of the upper clamp member comprises one or more dimples formedin a side surface thereof, the one or more dimples configured tofacilitate the holding open of the panel receiving gap.

In yet a further embodiment, the clamp assembly is capable of beingrotated 360 degrees relative to the base assembly of the support surfaceattachment device so as to accommodate various photovoltaic modulemounting arrangements.

In still a further embodiment, the clamp assembly is capable of beinginterchangeably used with or without a skirt member of a photovoltaicarray.

In yet a further embodiment, the upper clamp member of the clampassembly comprises at least one skirt receiving groove, the at least oneskirt receiving groove configured to receive a downwardly extending edgeportion of a skirt member.

In still a further embodiment, the fastener member is configured tosecure the skirt member to the clamp assembly.

In accordance with yet one or more other embodiments of the presentinvention, there is provided a coupling device configured to attach oneor more photovoltaic modules to one or more other photovoltaic modules.The coupling device includes a lower coupling member including at leastone ledge extending outwardly from a side surface of the lower couplingmember; and an upper coupling member including at least one flangeportion extending outwardly from the upper coupling member, the uppercoupling member being adjustably connected to the lower coupling memberby at least one fastening device, the at least one ledge of the lowercoupling member and the at least one flange portion of the uppercoupling member defining a panel receiving gap therebetween, the panelreceiving gap being continuously adjustable by a user within the rangebetween approximately 32 millimeters and approximately 50 millimeters soas to accommodate any photovoltaic module thickness within the range.

In a further embodiment of the present invention, the coupling devicefurther comprises integrated grounding means, the integrated groundingmeans configured to provide integrated grounding between adjacentphotovoltaic modules.

In yet a further embodiment, the integrated grounding means of thecoupling device comprises one or more grounding protrusions or teeth.

In still a further embodiment, the lower coupling member furthercomprises at least one drainage slot formed therethrough for drainingwater from the one or more photovoltaic modules.

In yet a further embodiment, the lower coupling member comprises one ormore water drainage channels formed therein for draining water from oneor more drainage weep holes of the one or more photovoltaic modules.

In still a further embodiment, the lower coupling member furthercomprises a plurality of extruded threads formed therein for threadinglyengaging a plurality of external threads of the at least one fasteningdevice.

In yet a further embodiment, the at least one ledge of the lowercoupling member comprises a pair of ledges extending outwardly fromoppositely disposed outer side surfaces of the lower coupling member,the at least one flange portion of the upper coupling member comprises apair of flange portions extending outwardly from oppositely disposedouter side surfaces of the upper coupling member, the pair of ledges ofthe lower coupling member and the pair of flange portions of the uppercoupling member allowing the coupling device to be rotated 180 degreesrelative to the one or more photovoltaic modules so that the couplingdevice is capable of being interchangeably used on north and south rowsof a photovoltaic array.

In still a further embodiment, the coupling device is capable of beinginterchangeably used with or without a skirt member of a photovoltaicarray.

In yet a further embodiment, the upper coupling member of the couplingdevice comprises at least one skirt receiving groove, the at least oneskirt receiving groove configured to receive a downwardly extending edgeportion of a skirt member.

In accordance with still one or more other embodiments of the presentinvention, there is provided a mounting system for supporting aplurality of photovoltaic modules on a support surface. The mountingsystem includes a support surface attachment device, the support surfaceattachment device configured to attach one or more photovoltaic modulesto a support surface, the support surface attachment device including aclamp assembly, the clamp assembly including a lower clamp member and anupper clamp member, at least one of the upper and lower clamp membersincluding a skirt receiving groove or notch formed therein; and a skirtmember, the skirt member including a downwardly extending edge portionconfigured to be received within the skirt receiving groove or notch ofthe at least one of the upper and lower clamp members, the engagementbetween the skirt member and the clamp assembly of the support surfaceattachment device being configured to allow the clamp assembly toaccommodate any photovoltaic module thickness within a range betweenapproximately 32 millimeters and approximately 50 millimeters.

In a further embodiment of the present invention, the skirt membercomprises a curled lower edge portion, the curled lower edge portion ofthe skirt member being configured to receive a pin member therein forfacilitating an alignment of multiple skirt sections in a photovoltaicarray.

In accordance with yet one or more other embodiments of the presentinvention, there is provided a support surface attachment device, thesupport surface attachment device configured to attach one or morephotovoltaic modules to a support surface. The support surfaceattachment device includes a base assembly configured to be attached toa support surface; and a clamp assembly configured to engage one or morephotovoltaic modules, the clamp assembly including a lower clamp memberand an upper clamp member, the upper clamp member connected to the lowerclamp member by a fastener member, the upper clamp member including oneor more first teeth disposed thereon, and the lower clamp memberincluding one or more second teeth disposed thereon, and the one or morefirst teeth on the upper clamp member configured to engage the one ormore second teeth on the lower clamp member when the fastener member isbeing tightened so as to provide one or more predetermined modulethickness settings in a range between 32 millimeters and 46 millimeters.

In a further embodiment of the present invention, the one or more firstteeth on the upper clamp member comprises a plurality of first teeth andthe one or more second teeth on the lower clamp member comprises aplurality of second teeth, a predetermined one of the plurality firstteeth on the upper clamp member configured to engage with apredetermined one of the plurality of second teeth on the lower clampmember when the fastener member is being tightened so as to providepredetermined settings for photovoltaic modules having the followingmodule thicknesses: 32 millimeters, 33 millimeters, 35 millimeters, 38millimeters, 40 millimeters, and 46 millimeters.

In yet a further embodiment, the support surface attachment devicefurther comprises a spring member disposed between the upper clampmember and the lower clamp member of the clamp assembly, the springmember configured to hold the clamp assembly open for facilitating theinstallation of the one or more photovoltaic modules into the clampassembly, and the spring member further configured to enable the clampassembly to be secured on the base assembly while maintaining theminimum gap between the upper clamp member and the lower clamp member.

In still a further embodiment, the upper clamp member further comprisesa flange portion and a vertical base portion extending downwardly fromthe flange portion, the flange portion of the upper clamp member havingan angled lower surface, the angled lower surface of the flange portionconfigured to interact with the spring member as so to displace thevertical base portion and the plurality of first teeth outwardly awayfrom the plurality of second teeth on the lower clamp member when thefastener member is being tightened until the desired module thicknesssetting pulls the upper clamp member into the lower clamp member.

In yet a further embodiment, the lower clamp member of the clampassembly comprises an upwardly tapered first ledge extending outwardlyfrom a first side of the clamp assembly, the upwardly tapered firstledge comprising an end portion of reduced thickness so as toaccommodate a wire retaining clip.

In still a further embodiment, the upwardly tapered ledge of the lowerclamp member comprises a water drainage trough formed therein fordraining water from the one or more photovoltaic modules.

In yet a further embodiment, the lower clamp member of the clampassembly further comprises a second ledge extending outwardly from asecond side of the clamp assembly, the second ledge being oppositelydisposed relative to the upwardly tapered first ledge.

In still a further embodiment, the second ledge of the lower clampmember comprises a groove formed therein for engaging with a matingprotrusion of a skirt spacer member.

In yet a further embodiment, the second ledge of the lower clamp memberfurther comprises a retaining element for retaining the skirt spacermember in place on the second ledge of the lower clamp member after themating protrusion of the skirt spacer member is engaged with the groovein the second ledge.

In still a further embodiment, the second ledge of the lower clampmember further comprises a plurality of serrations for securely grippingthe one or more photovoltaic modules and for providing airflow and waterdrainage on the second side of the clamp assembly.

In accordance with still one or more other embodiments of the presentinvention, there is provided a coupling device configured to attach oneor more photovoltaic modules to one or more other photovoltaic modules.The coupling device includes a lower coupling member including at leastone ledge extending outwardly from a side surface of the lower couplingmember; and an upper coupling member including at least one flangeportion extending outwardly from the upper coupling member, the uppercoupling member being adjustably connected to the lower coupling memberby at least one fastener member, the upper coupling member including oneor more first teeth disposed thereon, and the lower coupling memberincluding one or more second teeth disposed thereon, and the one or morefirst teeth on the upper coupling member configured to engage the one ormore second teeth on the lower coupling member when the at least onefastener member is being tightened so as to provide one or morepredetermined module thickness settings in a range between 32millimeters and 46 millimeters.

In a further embodiment of the present invention, the one or more firstteeth on the upper coupling member comprises a plurality of first teethand the one or more second teeth on the lower coupling member comprisesa plurality of second teeth, a predetermined one of the plurality firstteeth on the upper coupling member configured to engage with apredetermined one of the plurality of second teeth on the lower couplingmember when the fastener is being tightened so as to providepredetermined settings for photovoltaic modules having the followingmodule thicknesses: 32 millimeters, 33 millimeters, 35 millimeters, 38millimeters, 40 millimeters, and 46 millimeters.

In yet a further embodiment, the upper coupling member further comprisesa vertical base portion extending downwardly from the at least oneflange portion, the at least one flange portion of the upper couplingmember having an angled lower surface, the angled lower surface of theat least flange portion being substantially equivalent to an angledlower surface of a flange portion of an upper clamp member of a supportsurface attachment device so as to allow the same extrusion profile tobe used for both the upper coupling member and the upper clamp member ofthe support surface attachment device.

In still a further embodiment, the at least one ledge of the lowercoupling member comprises an end portion of reduced thickness so as toaccommodate a wire retaining clip.

In yet a further embodiment, the at least one ledge of the lowercoupling member comprises a water drainage trough formed therein fordraining water from the one or more photovoltaic modules.

In still a further embodiment, the at least one ledge of the lowercoupling member comprises an upwardly tapered first ledge and a secondledge, the second ledge being oppositely disposed relative to theupwardly tapered first ledge.

In yet a further embodiment, the second ledge of the lower couplingmember comprises a groove formed therein for engaging with one or moremating protrusions of one or more respective skirt spacer members.

In still a further embodiment, the second ledge of the lower couplingmember further comprises one or more retaining elements for retainingthe one or more skirt spacer members in place on the second ledge of thelower coupling member after the one or more mating protrusions of theone or more respective skirt spacer members is engaged with the groovein the second ledge.

In yet a further embodiment, the second ledge of the lower couplingmember further comprises a plurality of serrations for securely grippingthe one or more photovoltaic modules and for providing airflow and waterdrainage on the side of the coupling device with the second ledge.

In accordance with yet one or more other embodiments of the presentinvention, there is provided a mounting system for supporting aplurality of photovoltaic modules on a support surface. The mountingsystem includes a support surface attachment device, the support surfaceattachment device configured to attach one or more photovoltaic modulesto a support surface, the support surface attachment device including aclamp assembly, the clamp assembly including a lower clamp member and anupper clamp member, the lower clamp member having an outwardly extendingcomponent extending from an outer side of the lower clamp member; askirt member, the skirt member configured to be supported by the clampassembly; and a skirt spacer member, the skirt spacer member configuredto be disposed between a portion of the skirt member and the outwardlyextending component of the lower clamp member so as to elevate the skirtmember above a top surface of the outwardly extending component, theskirt spacer member configured to enable the skirt member to beinterchangeably used with a plurality of different photovoltaic modulethicknesses ranging from 32 millimeters to 46 millimeters.

In a further embodiment of the present invention, the skirt membercomprises a vertical skirt leg extending downwardly from an upper endportion of the skirt member, the vertical skirt leg configured to retainthe skirt member between the skirt spacer member and the lower clampmember during the installation of the skirt member until the skirtmember is secured in the clamp assembly between the upper and lowerclamp members.

In yet a further embodiment, the skirt spacer member is one of aplurality of skirt spacer members having different sizes, respectiveones of the plurality of skirt spacer members being sized to accommodatephotovoltaic modules having the following module thicknesses: 32millimeters, 33 millimeters, 35 millimeters, 38 millimeters, 40millimeters, and 46 millimeters.

In still a further embodiment, each of the plurality of skirt spacermembers comprises indicia for indicating the spacer size.

In yet a further embodiment, the outwardly extending component of thelower clamp member comprises a groove formed therein for engaging with amating protrusion of the skirt spacer member, the engagement between themating protrusion of the skirt spacer member and the groove of the lowerclamp member configured to secure the skirt spacer member in place onthe lower clamp member.

In still a further embodiment, the mounting system further comprises amodule coupling device, the module coupling device configured to attachone or more photovoltaic modules to one or more other photovoltaicmodules; and the mounting system additionally comprises a pair of skirtspacer members configured to be disposed between a portion of the skirtmember and an outwardly extending ledge of the module coupling device soas to elevate the skirt member above a top surface of the outwardlyextending ledge.

It is to be understood that the foregoing general description and thefollowing detailed description of the present invention are merelyexemplary and explanatory in nature. As such, the foregoing generaldescription and the following detailed description of the inventionshould not be construed to limit the scope of the appended claims in anysense.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention will now be described, by way of example, with referenceto the accompanying drawings, in which:

FIG. 1 is a perspective view of a support surface attachment device of aphotovoltaic mounting system, according to a first embodiment of theinvention, wherein the support surface attachment device is illustratedin an assembled state;

FIG. 2 is another perspective view of the support surface attachmentdevice of FIG. 1, wherein a clamp assembly of the support surfaceattachment device is shown exploded from a base assembly of the supportsurface attachment device;

FIG. 3 is a perspective view of the clamp assembly of the supportsurface attachment device of FIG. 1, wherein the clamp assembly isillustrated in an assembled state;

FIG. 4 is another perspective view of the clamp assembly of the supportsurface attachment device of FIG. 1, wherein the components of the clampassembly are shown exploded from one another;

FIG. 5 is a perspective view of a fastener member of the clamp assemblyof FIG. 3;

FIG. 6 is a perspective view of an upper clamp member of the clampassembly of FIG. 3;

FIG. 7 is a perspective view of a bonding clip of the clamp assembly ofFIG. 3;

FIG. 8 is a perspective view of a sleeve member of the clamp assembly ofFIG. 3;

FIG. 9 is a perspective view of a lower clamp member of the clampassembly of FIG. 3;

FIG. 10 is a perspective view of a washer of the clamp assembly of FIG.3;

FIG. 11 is a perspective view of a glider member of the clamp assemblyof FIG. 3;

FIG. 12 is a bottom perspective view of a strut nut of the clampassembly of FIG. 3;

FIG. 13 is a top plan view of the strut nut of FIG. 12;

FIG. 14 is a perspective view of the base assembly of the supportsurface attachment device of FIG. 1, wherein the base assembly isillustrated in an assembled state;

FIG. 15 is another perspective view of the base assembly of the supportsurface attachment device of FIG. 1, wherein the components of the baseassembly are shown exploded from one another;

FIG. 16 is a perspective view of a fastener member of the base assemblyof FIG. 14;

FIG. 17 is a perspective view of an upper sealing washer of the baseassembly of FIG. 14;

FIG. 18 is a perspective view of an upstanding base member of the baseassembly of FIG. 14;

FIG. 19 is a perspective view of a lower sealing washer of the baseassembly of FIG. 14;

FIG. 20 is a perspective view of a flashing member of the base assemblyof FIG. 14;

FIG. 21 is a perspective view of a coupling device of a photovoltaicmounting system, according to a first embodiment of the invention,wherein the coupling device is illustrated in an assembled state;

FIG. 22 is another perspective view of the coupling device of FIG. 21,wherein the components forming the coupling device are shown explodedfrom one another;

FIG. 23 is a perspective view of an upper coupling member of thecoupling device of FIG. 21;

FIG. 24 is a perspective view of a lower coupling member of the couplingdevice of FIG. 21;

FIG. 25 is a perspective view of a captive nut of the coupling device ofFIG. 21;

FIG. 26 is a perspective view illustrating the support surfaceattachment device of FIG. 1 together with the coupling device of FIG. 21and a lower skirt member connected to the support surface attachmentdevice and the coupling device;

FIG. 27 is an end view of the assembly of FIG. 26, wherein the supportsurface attachment device and lower skirt member are shown;

FIG. 28 is a perspective view of a lower skirt member, similar to thelower skirt member illustrated in FIG. 26;

FIG. 29 is a perspective view of a support surface attachment device ofa photovoltaic mounting system, according to a second embodiment of theinvention, wherein the support surface attachment device is illustratedin an assembled state;

FIG. 30 is a perspective view of an upper clamp member of the clampassembly of the support surface attachment device of FIG. 29;

FIG. 31 is a perspective view of a bonding clip of the clamp assembly ofthe support surface attachment device of FIG. 29;

FIG. 32 is a perspective view of a lower clamp member of the clampassembly of the support surface attachment device of FIG. 29;

FIG. 33 is a perspective view of a glider member of the clamp assemblyof the support surface attachment device of FIG. 29;

FIG. 34 is a perspective view of the base assembly of the supportsurface attachment device of FIG. 29, wherein the base assembly isillustrated in an assembled state;

FIG. 35 is a perspective view of an upstanding base member of the baseassembly of FIG. 34;

FIG. 36 is a perspective view of a washer of the clamp assembly of thesupport surface attachment device of FIG. 29;

FIG. 37 is a perspective view of a flashing member of the base assemblyof FIG. 34;

FIG. 38 is an end view of a lower skirt member, according to anotherembodiment of the invention;

FIG. 39 is an end view of a lower skirt member, similar to the lowerskirt member illustrated in FIG. 38, according to yet another embodimentof the invention;

FIG. 40 is a perspective view of a coupling device of a photovoltaicmounting system, according to a second embodiment of the invention,wherein the coupling device is illustrated in an assembled state;

FIG. 41 is a perspective view of an upper coupling member of thecoupling device of FIG. 40;

FIG. 42 is a perspective view of a lower coupling member of the couplingdevice of FIG. 40;

FIG. 43 is a perspective view of the clamp assembly of the supportsurface attachment device of FIG. 29, wherein the clamp assembly isillustrated in an assembled state;

FIG. 44 is an exploded view of the clamp assembly of FIG. 43;

FIG. 45 is a perspective view of an upper clamp member of the clampassembly of the support surface attachment device, according to analternative embodiment of the invention;

FIG. 46 is a side view of the upper clamp member of FIG. 46;

FIG. 47 is a perspective view of a bonding clip, according to analternative embodiment of the invention;

FIG. 48 is a perspective view of a junction box bracket attached to abase member, according to one embodiment of the invention;

FIG. 49 is a perspective view of a junction box bracket kit, accordingto another embodiment of the invention;

FIG. 50 is a perspective view of the junction box bracket of thejunction box bracket kit of FIG. 49;

FIG. 51 is a perspective view of a micro-inverter mounting plateattached to the frame of a photovoltaic module by a power accessorybracket assembly, according to an embodiment of the invention;

FIG. 52 is a perspective view of the power accessory bracket assembly ofFIG. 51, wherein the power accessory bracket assembly is in an assembledstate;

FIG. 53 is an exploded view of the power accessory bracket assembly ofFIG. 52;

FIG. 54 is a perspective view of a captive nut of the power accessorybracket assembly of FIG. 52;

FIG. 55 is a perspective view of a power accessory bracket of the poweraccessory bracket assembly of FIG. 52;

FIG. 56 is a perspective view of a threaded fastener member of the poweraccessory bracket assembly of FIG. 52;

FIG. 57 is a perspective view of a north row extension assembly,according to an embodiment of the invention;

FIG. 58 is an exploded view of the north row extension assembly of FIG.57;

FIG. 59 is a perspective view of a captive nut of the north rowextension assembly of FIG. 57;

FIG. 60 is a perspective view of an upper end clamp member of the northrow extension assembly of FIG. 57;

FIG. 61 is a perspective view of an end clamp fastener member of thenorth row extension assembly of FIG. 57;

FIG. 62 is a perspective view of a strut fastener member of the northrow extension assembly of FIG. 57;

FIG. 63 is a perspective view of a north row extension member of thenorth row extension assembly of FIG. 57;

FIG. 64 is a perspective view of an upstanding tile base member,according to an embodiment of the invention;

FIG. 65 is a perspective view of a south row mounting assembly,according to an embodiment of the invention;

FIG. 66 is an exploded view of the south row mounting assembly of FIG.65;

FIG. 67 is a perspective view of an elongated glider member of the southrow mounting assembly of FIG. 65;

FIG. 68 is a perspective view of a south row coupling assembly of aphotovoltaic mounting system, according to an embodiment of theinvention, wherein the coupling assembly is illustrated in an assembledstate;

FIG. 69 is an exploded view of the south row coupling assembly of FIG.68;

FIG. 70 is a perspective view of an upper coupling member of the southrow coupling assembly of FIG. 68;

FIG. 71 is a perspective view of an lower coupling member of the southrow coupling assembly of FIG. 68;

FIG. 72 is an end view illustrating the support surface attachmentdevice of FIG. 29 together with a lower skirt member connected to thesupport surface attachment device, according to an embodiment of theinvention;

FIG. 73 is a perspective view of a first spring member that may beutilized in the clamp assembly of FIGS. 43 and 44, according to oneembodiment of the invention;

FIG. 74 is a perspective view of a second spring member that may beutilized in the clamp assembly of FIGS. 43 and 44, according to anotherembodiment of the invention;

FIG. 75 is a side view of the upper clamp member of FIGS. 45 and 46together with a bonding clip attached thereto, according to anembodiment of the invention;

FIG. 76 is a perspective view of an upper sealing washer of the baseassembly of FIGS. 34 and 78, according to an embodiment of theinvention;

FIG. 77 is a sectional view cut through the upper sealing washer of FIG.76;

FIG. 78 is a partial sectional view cut through the base assembly ofFIG. 34, wherein sealing engagement between the base member and theflashing member is shown;

FIG. 79 is a perspective view of a junction box bracket, according toyet another embodiment of the invention;

FIG. 80 is a perspective view of the junction box bracket of FIG. 79attached to a base member;

FIG. 81 is a perspective view of a bonding clip, according to anotheralternative embodiment of the invention;

FIG. 82 is a perspective view of a north row extension assembly,according to an alternative embodiment of the invention;

FIG. 83 is an exploded view of the north row extension assembly of FIG.82;

FIG. 84 is a perspective view of a junction box bracket, according tostill another embodiment of the invention;

FIG. 85 is a perspective view of a lower coupling member of a couplingdevice, according to an alternative embodiment;

FIG. 86 is a perspective view of a conduit mounting member, according toan embodiment of the invention;

FIG. 87 is a perspective view of an upstanding tile base member,according to an alternative embodiment of the invention; and

FIG. 88 is a perspective view of the illustrative mounting systemdescribed herein being used to secure an array of photovoltaic modulesto a sloped roof;

FIG. 89 is an exploded perspective view of another clamp assembly usedin conjunction with the support surface attachment devices describedherein, according to another embodiment of the invention;

FIG. 90 is a side view of the clamp assembly of FIG. 89, wherein theclamp assembly is in its assembled state;

FIG. 91 is an end view of the clamp assembly of FIG. 90;

FIG. 92 is a perspective view of the clamp assembly of FIG. 90;

FIG. 93 is a top plan view of the clamp assembly of FIG. 90;

FIG. 94 is an exploded perspective view of yet another clamp assemblyused in conjunction with the support surface attachment devicesdescribed herein, according to yet another embodiment of the invention;

FIG. 95 is a top plan view of the clamp assembly of FIG. 94, wherein theclamp assembly is in its assembled state;

FIG. 96 is an end view of the clamp assembly of FIG. 95;

FIG. 97 is a side view of the clamp assembly of FIG. 95;

FIG. 98 is a perspective view of the clamp assembly of FIG. 95;

FIG. 99 is a perspective view of the lower clamp member of the clampassembly of FIG. 94;

FIG. 100 is a side view of the lower clamp member of FIG. 99;

FIG. 101 is a top plan view of the lower clamp member of FIG. 99;

FIG. 102 is an end view of the lower clamp member of FIG. 99;

FIG. 103 is a perspective view of the lower clamp member of the clampassembly of FIG. 89;

FIG. 104A is a side view of the lower clamp member of FIG. 103;

FIG. 104B is an enlarged perspective view of the skirt receiving notchof the lower clamp member illustrated in the side view of FIG. 104A(Detail “A”);

FIG. 105 is a top plan view of the lower clamp member of FIG. 103;

FIG. 106 is an end view of the lower clamp member of FIG. 103;

FIG. 107A is a perspective view of the upper clamp member of the clampassembly of FIG. 89;

FIG. 107B is an enlarged perspective view of one of the groundingprotrusions of the upper clamp member illustrated in the perspectiveview of FIG. 107A (Detail “B”);

FIG. 108 is a side view of the upper clamp member of FIG. 107A;

FIG. 109 is an end view of the upper clamp member of FIG. 107A;

FIG. 110 is a top plan view of the upper clamp member of FIG. 107A;

FIG. 111A is a perspective view of another upper clamp member used inconjunction with the clamp assemblies described herein, according toanother embodiment of the invention;

FIG. 111B is an enlarged perspective view of one of the groundingprotrusions of the upper clamp member illustrated in the perspectiveview of FIG. 111A (Detail “C”);

FIG. 112 is a top plan view of the upper clamp member of FIG. 111A;

FIG. 113 is a side view of the upper clamp member of FIG. 111A;

FIG. 114 is an end view of the upper clamp member of FIG. 111A;

FIG. 115A is a perspective view of yet another upper clamp member usedin conjunction with the clamp assemblies described herein, according toyet another embodiment of the invention;

FIG. 115B is an enlarged perspective view of one of the groundingprotrusions and the skirt receiving groove of the upper clamp memberillustrated in the perspective view of FIG. 115A (Detail “D”);

FIG. 116 is an end view of the upper clamp member of FIG. 115A;

FIG. 117 is a side view of the upper clamp member of FIG. 115A;

FIG. 118 is a top plan view of the upper clamp member of FIG. 115A;

FIG. 119A is a perspective view of still another upper clamp member usedin conjunction with the clamp assemblies described herein, according tostill another embodiment of the invention;

FIG. 119B is an enlarged perspective view of one of the groundingprotrusions and the skirt receiving groove of the upper clamp memberillustrated in the perspective view of FIG. 119A (Detail “E”);

FIG. 120 is a top plan view of the upper clamp member of FIG. 119A;

FIG. 121 is a side view of the upper clamp member of FIG. 119A;

FIG. 122 is an end view of the upper clamp member of FIG. 119A;

FIG. 123A is a perspective view of the upper clamp member of the clampassembly of FIG. 94;

FIG. 123B is an enlarged perspective view of the grounding protrusionsand the skirt receiving groove of the upper clamp member illustrated inthe perspective view of FIG. 123A (Detail “F”);

FIG. 124 is an end view of the upper clamp member of FIG. 123A;

FIG. 125 is a side view of the upper clamp member of FIG. 123A;

FIG. 126 is a top plan view of the upper clamp member of FIG. 123A;

FIG. 127 is an exploded perspective view of another coupling device,according to another embodiment of the invention;

FIG. 128 is a side view of the coupling device of FIG. 127, wherein thecoupling device is in its assembled state;

FIG. 129 is an end view of the coupling device of FIG. 128;

FIG. 130 is a perspective view of the coupling device of FIG. 128;

FIG. 131 is a top plan view of the coupling device of FIG. 128;

FIG. 132 is a perspective view of the lower coupling member of thecoupling device of FIG. 127;

FIG. 133 is a top plan view of the lower coupling member of FIG. 132;

FIG. 134 is a side view of the lower coupling member of FIG. 132;

FIG. 135 is an end view of the lower coupling member of FIG. 132;

FIG. 136 is a top plan view of the upper coupling member of the couplingdevice of FIG. 127;

FIG. 137 is an end view of the upper coupling member of FIG. 136;

FIG. 138 is a side view of the upper coupling member of FIG. 136;

FIG. 139A is a perspective view of the upper coupling member of FIG.136;

FIG. 139B is an enlarged perspective view of two of the groundingprotrusions and the skirt receiving grooves of the upper coupling memberillustrated in the perspective view of FIG. 139A (Detail “G”);

FIG. 140A is a rear perspective view illustrating a support surfaceattachment device with the clamp assembly of FIG. 94 together with thecoupling device of FIG. 127 and a lower skirt member connected to thesupport surface attachment device and the coupling device;

FIG. 140B is an enlarged side view illustrating the securement of theskirt member in the skirt receiving groove of the upper clamp member ofFIG. 140A;

FIG. 141A is an enlarged side view illustrating the securement of theskirt member in the skirt receiving groove of the upper coupling memberof FIG. 140A;

FIG. 141B is a front perspective view of the support surface attachmentdevice, coupling device, and lower skirt member of FIG. 140A;

FIG. 142 is an exploded perspective view of the support surfaceattachment device, coupling device, and lower skirt member of FIG. 140A,wherein the skirt member has been exploded from the support surfaceattachment device and the coupling device;

FIG. 143 is a rear perspective view of the lower skirt memberillustrated in FIG. 140A;

FIG. 144 is a front view of the lower skirt member of FIG. 143;

FIG. 145A is an enlarged partial end view illustrating the hemmed upperedge portion of the lower skirt member of FIG. 143;

FIG. 145B is an end view of the lower skirt member of FIG. 143;

FIG. 145C is an enlarged partial end view illustrating the curled loweredge portion of the lower skirt member of FIG. 143;

FIG. 146 is a top plan view of the lower skirt member of FIG. 143;

FIG. 147 is a top perspective view illustrating another coupling devicejoining two adjacent photovoltaic modules to one another, according toanother embodiment of the invention;

FIG. 148 is a perspective view of another lower coupling member,according to another embodiment of the invention, wherein the lowercoupling member is configured to be used on the row of photovoltaicmodules with the lower skirt member;

FIG. 149 is an end view of the lower coupling member of FIG. 148;

FIG. 150 is a top perspective view illustrating the lower couplingmember of FIG. 148 joining two adjacent photovoltaic modules to oneanother;

FIG. 151 is a side view of another clamp assembly, according to anotherembodiment of the invention, wherein a lower skirt member is shownattached to the clamp assembly;

FIG. 152 is a perspective view of the lower clamp member of the clampassembly of FIG. 151;

FIG. 153 is a side view of the lower clamp member of FIG. 152;

FIG. 154 is a perspective view of another lower clamp member, accordingto another embodiment of the invention, the lower clamp member beingused for attaching a lower skirt member to a photovoltaic array;

FIG. 155 is a side view of the lower clamp member of FIG. 154;

FIG. 156 is an end view of a lower skirt member attached to a supportsurface attachment device, wherein the lower clamp member of FIG. 154 isbeing used to secure the lower skirt member to the support surfaceattachment device;

FIG. 157 is an end view of a lower skirt member attached to a supportsurface attachment device, wherein the support surface attachment devicecomprises a clamp assembly similar to that illustrated in FIG. 89, andwherein a spacer member is being used to hold the clamp assembly open;

FIG. 158 is a perspective view of the spacer member utilized in theassembly of FIG. 157;

FIG. 159 is an end view of the lower skirt member utilized in theassembly of FIG. 157;

FIG. 160 is an end view of a lower skirt member attached to a supportsurface attachment device, wherein the support surface attachment devicecomprises the clamp assembly of FIG. 89;

FIG. 161 is an end view of the lower skirt member utilized in theassembly of FIG. 160;

FIG. 162 is a perspective view of another spacer member utilized in theclamp assemblies described herein, according to another embodiment ofthe invention;

FIG. 163 is a side view of the spacer member of FIG. 162;

FIG. 164 is another exploded perspective view of the support surfaceattachment device, coupling device, and lower skirt member of FIG. 140A,wherein the skirt member has been exploded from the support surfaceattachment device and the coupling device;

FIG. 165 is a rear elevational view of the support surface attachmentdevice, coupling device, and lower skirt member of FIG. 164;

FIG. 166 is a side view of the coupling device of FIG. 164, whereinspacer members are provided in the coupling device for holding thecoupling device open;

FIG. 167 is an end view of the clamp assembly of FIG. 164 illustratingthe spacer member in the clamp assembly for holding the clamp assemblyopen;

FIG. 168 is an enlarged side view illustrating the securement of theskirt member in the skirt receiving groove of the upper clamp member ofFIG. 164;

FIG. 169 is a perspective view of yet another spacer member utilized inthe clamp assemblies described herein, according to yet anotherembodiment of the invention;

FIG. 170 is an enlarged side view illustrating the securement of theskirt member in the skirt receiving groove of the upper coupling memberof FIG. 164;

FIG. 171 is a perspective view of yet another clamp assembly of asupport surface attachment device of a photovoltaic mounting system,according to yet another embodiment of the invention, wherein the clampassembly is illustrated in an assembled state;

FIG. 172 is another perspective view of the clamp assembly of thesupport surface attachment device of FIG. 171, wherein the components ofthe clamp assembly are shown exploded from one another;

FIG. 173 is a perspective view of a fastener member of the clampassembly of FIG. 171;

FIG. 174 is a side elevational view of an upper clamp member of theclamp assembly of FIG. 171;

FIG. 175 is a perspective view of the upper clamp member of the clampassembly of FIG. 171;

FIG. 176 is a perspective view of a bonding clip of the clamp assemblyof FIG. 171;

FIG. 177 is a perspective view of a spring member of the clamp assemblyof FIG. 171;

FIG. 178 is a side elevational view of a lower clamp member of the clampassembly of FIG. 171;

FIG. 179 is a perspective view of the lower clamp member of the clampassembly of FIG. 171;

FIG. 180 is a perspective view of a glider member of the clamp assemblyof FIG. 171;

FIG. 181 is a side elevational view of the glider member of the clampassembly of FIG. 171;

FIG. 182 illustrates a side view and top view of an O-ring of the clampassembly of FIG. 171;

FIG. 183 is a top perspective view of a strut nut of the clamp assemblyof FIG. 171;

FIG. 184 is a perspective view of yet another coupling device of aphotovoltaic mounting system, according to yet another embodiment of theinvention, wherein the coupling device is illustrated in an assembledstate;

FIG. 185 is another perspective view of the coupling device of FIG. 184,wherein the components forming the coupling device are shown explodedfrom one another;

FIG. 186 is a side view of a fastener member of the coupling device ofFIG. 184;

FIG. 187 is an end view of an upper coupling member of the couplingdevice of FIG. 184;

FIG. 188 is a perspective view of the upper coupling member of thecoupling device of FIG. 184;

FIG. 189 is an end view of the lower coupling member of the couplingdevice of FIG. 184;

FIG. 190 is a perspective view of the lower coupling member of thecoupling device of FIG. 184;

FIG. 191 is an end view illustrating the clamp assembly of FIG. 171together with a skirt member and a skirt spacer member that are securedwithin the clamp assembly, the skirt spacer member of FIG. 191 beingconfigured to accommodate a first photovoltaic module thickness;

FIG. 192 is an end view illustrating the clamp assembly of FIG. 171together with the skirt member and another skirt spacer member that aresecured within the clamp assembly, the skirt spacer member of FIG. 192being configured to accommodate a second photovoltaic module thickness;

FIG. 193 is an end view of the skirt member depicted in FIGS. 191 and192;

FIG. 194 is a perspective view of the skirt member depicted in FIGS. 191and 192;

FIG. 195 is an end view of a first skirt spacer member configured toaccommodate photovoltaic modules having a first thickness;

FIG. 196 is a perspective view of the first skirt spacer memberillustrated in FIG. 195;

FIG. 197 is an end view of a second skirt spacer member configured toaccommodate photovoltaic modules having a second thickness;

FIG. 198 is a perspective view of the second skirt spacer memberillustrated in FIG. 197;

FIG. 199 is an end view of a third skirt spacer member configured toaccommodate photovoltaic modules having a third thickness; and

FIG. 200 is a perspective view of the third skirt spacer memberillustrated in FIG. 199.

Throughout the figures, the same parts are always denoted using the samereference characters so that, as a general rule, they will only bedescribed once.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

An first illustrative embodiment of the support surface attachmentdevice is seen generally at 100 in FIGS. 1 and 2. In one or moreembodiments, a plurality of support surface attachment devices 100 areused to securely attach an array of photovoltaic modules to a supportsurface (e.g., a sloped building roof). Referring to FIG. 2, it can beseen that support surface attachment device 100 generally comprises aclamp assembly 126 and a base assembly 128. Each of these assemblies126, 128 will be described in detail hereinafter.

Initially, with reference to FIGS. 3-13, it can be seen that theillustrative embodiment of the clamp assembly 126 generally includes anupper clamp member 10, a lower clamp member 20, and a glider member 60.As best shown in the assembled view of FIG. 3, the upper clamp member10, lower clamp member 20, and glider member 60 are connected to oneanother by means of a threaded fastener member 38 and a strut nut 72. Inthe illustrated embodiment, the threaded fastener member 38 is in theform of a bolt with a head portion having a serrated flange 40 (refer toFIG. 5). The serrations in the lower surface of the bolt head flange ofthe threaded fastener member 38 are configured to interferingly engagewith the top surface of the upper clamp member 10 (i.e., “dig into” thetop surface of the upper clamp member 10). The external threads on theshaft of the threaded fastener member 38 are configured to threadinglyengage with the internal threads 74 in the middle of the strut nut 72(see FIG. 12). As shown in FIGS. 12 and 13, the strut nut 72 hasspaced-apart elongate grooves 76 disposed in the top surface thereofthat are each configured to receive a respective downturned lip 108 ofthe base member 90, which will be described hereinafter. In addition, asbest shown in the top view of FIG. 13, it can be seen that each of theelongate grooves 76 is provided with two (2) spaced-apart protrusions orteeth 77 disposed therein. The spaced-apart teeth 77 in each groove 76are configured to interferingly engage with a bottom surface of one ofthe downturned lips 108 (i.e., “dig into” the bottom surface of one ofthe downturned lips 108). Also, referring collectively to FIGS. 12 and13, it can be seen that the strut nut 72 comprises curved sidewallportions 78 arranged diagonally opposite from one another. The curvedsidewall portions 78 allow the strut nut 72 to rotate clockwise intoposition until the flat sidewall portions contact the inside walls ofthe base member 90.

Referring again to the illustrative embodiment of FIG. 3, it can be seenthat the upper clamp member 10 and the lower clamp member 20 of clampassembly 126 cooperate to clamp one or more photovoltaic modules inplace on a support surface. That is, each photovoltaic module is clampedin place either between the first opposed flange portion 14 a of theupper clamp member 10 and the second outwardly extending ledge 28 of thelower clamp member 20 or between the second opposed flange portion 14 bof the upper clamp member 10 and the first outwardly extending ledge 26of the lower clamp member 20, depending on which side of the clampassembly 126 the photovoltaic module is disposed.

Now, with reference to FIG. 6, the structure of the upper clamp member10 will be described. As shown in this figure, the upper clamp member 10generally includes a base portion 12 that is attached to the bottomsurface of a flange portion 14 a, 14 b at approximately a 90 degreeangle. In this figure, it can be seen that one side surface of baseportion 12 comprises a plurality of elongate protrusions or teeth 18that are each spaced apart from one another by respective elongategrooves 19. As will be described hereinafter, the plurality of elongateprotrusions or teeth 18 matingly engage with elongate protrusions orteeth 30 disposed on the first opposed wall portion 24 a of theupstanding middle portion 22 of the lower clamp member 20. Referringagain to FIG. 6, it can be seen that the flange portion 14 a, 14 b ofthe upper clamp member 10 further comprises a fastener aperture 15 forreceiving the threaded fastener member 38 and a downwardly protrudingmember 17 that forms a back surface against which a photovoltaic modulerests when disposed in the clamp assembly 126. Also, as shown in FIG. 6,each of the flange portions 14 a, 14 b includes an elongate groove 16disposed in the bottom surface thereof. Each of the elongate grooves 16is configured to receive a trough portion 48 of a respective bondingclip 42 (see FIG. 7) that provides integrated grounding for thephotovoltaic module installation. The trough portion 48 of eachrespective bonding clip 42 is received within its respective elongategroove 16 in a press-fit or interference-fit type mounting arrangement.

The bonding or grounding clip 42, which provides integrated groundingfor the photovoltaic modules, is illustrated in FIG. 7. The bonding clip42 generally comprises a plate-like body portion with a trough portion48 extending laterally across the plate-like body portion and dividingthe plate-like body portion into two sections. In FIG. 7, it can be seenthat the plate-like body portion includes one or more upwardlyprotruding annular members 44 and one or more downwardly protrudingannular members 46. In particular, in the illustrative embodiment, theupwardly and downwardly protruding annular members 44, 46 are arrangedin an alternating sequence (i.e., a first upwardly protruding annularmember 44 followed by a downwardly protruding annular member 46, thenfollowed by a second upwardly protruding annular member 44). Theupwardly protruding members 44 are designed to pierce the metallicbottom surface of the flange portion 14 a, 14 b of the upper clampmember 10, while the downwardly protruding annular member 46 is designedto pierce the anodized layer of the photovoltaic module to provideintegrated grounding between the photovoltaic modules. To facilitateintegrated grounding between the photovoltaic modules, all of thecomponents of the support surface attachment device 100 and the couplingdevice 130 may be formed from metal.

Next, turning to FIG. 9, the structure of the lower clamp member 20 willbe explained. With reference to this figure, it can be seen that thelower clamp member 20 generally includes an upstanding middle portion 22with first and second ledge portions 26, 28 extending outwardly from theupstanding middle portion 22. In FIG. 9, it can be seen that theupstanding middle portion 22 of the lower clamp member 20 comprises alower fastener aperture 21 disposed in a bottom wall portion thereof,and an upper fastener aperture 25 disposed in a top wall portion 23thereof. Each of these apertures 21, 25 receives the shaft of thethreaded fastener member 38. The bottom wall portion and the top wallportion 23 of the upstanding middle portion 22 of the lower clamp member20 are connected to one another by first and second opposed wallportions 24 a, 24 b. As shown in FIG. 9, the first opposed wall portion24 a comprises a plurality of elongate protrusions or teeth 30 that areeach spaced apart from one another by respective elongate grooves 32. Asexplained above, the elongate teeth 30 of the first opposed wall portion24 a engage with the elongate teeth 18 of the base portion 12 of theupper clamp member 10. Referring again to FIG. 9, it can be seen thatthe second opposed wall portion 24 b comprises a plurality of elongatehook-shaped upwardly inclined protrusions or teeth 34 that are eachspaced apart from one another by respective elongate grooves 36. Thehook-shaped teeth 34 on the second opposed wall portion 24 b areconfigured to engage with a wind deflector and/or a mounting skirt fordeflecting wind up and over the photovoltaic array and/or improving theaesthetics of the array. Each of the first and second ledge portions 26,28 of the lower clamp member 20 is configured to accommodate aphotovoltaic module frame member resting thereon.

With reference to FIGS. 3, 4, and 9, it can be seen that the secondopposed ledge 28 of the lower clamp member 20 is bent slightly upward oris tapered slightly upward at an acute angle. In the installed state,the upwardly tapered ledge 28 of the lower clamp member 20 extendsuphill and slightly up and away from the building roof so as to act as aleaf spring that takes up the difference in gap between the uphill clampopening and the photovoltaic (PV) module thickness, thereby preventingthe PV module from rattling and allowing it to be secured into place. Insome embodiments, this also creates enough pressure on the upper clamplip (i.e., first opposed flange portion 14 a of upper clamp member 10)to enable a bonding point to function. Advantageously, because thesecond opposed ledge 28 of the lower clamp member 20 is provided with aslight upward taper (i.e., bowed upwardly), the lower clamp member 20applies a compressive force against the PV module when it is installedtherein. During the installation of each PV module, the PV module isinitially disposed at an upward acute angle relative to its one or moresouthern clamp assemblies 126. Then, each PV module is rotated downuntil it is generally parallel with the roof surface. As each PV moduleis rotated downwardly towards the roof surface, the edge portion of theuphill PV module presses down on the upwardly tapered ledge(s) 28 of thelower clamp member(s) 20 so as to apply a downward force on the upwardlytapered ledge 28, thereby ensuring that the PV module is securelyengaged with the lower clamp member(s) 20 and the PV module is tightlyheld in place. In response to the downward force applied by the PVmodule, the upwardly tapered ledges 28 elastically deforms or yields ina spring-like manner. As a result of the leaf spring design of theupwardly tapered ledge 28, the installer is not required to reach downover the PV module to tighten the fasteners on its one or more southernclamp assemblies 126. An attempt by the installer to tighten thefasteners on the one or more southern clamp assemblies 126 would not besafe, ergonomic, or efficient. The second ledge portion 158 of the lowercoupling member 150 may be bent slightly upward or tapered slightlyupward at an acute angle in the same manner as that described above forthe upwardly tapered ledge 28 of the lower clamp member 20 so that thecoupling device 130 is provided with the same functionality that isdescribed above for the clamp assembly 126.

In order to maintain a predetermined spacing distance between the upperand lower clamp members 10, 20, a sleeve member 50 is provided betweenthe clamp members 10, 20 (refer to FIGS. 3 and 4). That is, as bestshown in FIG. 3, the sleeve member 50 is disposed between the top wallportion 23 of the lower clamp member 20 and the bottom surface of theflange portion 14 a, 14 b of the upper clamp member 10. Turning to FIG.8, it can be seen that the sleeve member 50 of the clamp assembly 126comprises a cylindrical recess 52 extending therethrough for receivingthe shaft of the threaded fastener member 38. In an alternativeembodiment, a spring may be used rather than the sleeve member 50 tomaintain the predetermined spacing distance between the upper and lowerclamp members 10, 20.

As best shown in FIG. 3, the lower clamp member 20 is positioned above aglider member 60 that is configured to be adjustably disposed on theupstanding base member 90 in both a horizontal and vertical direction,as will be explained hereinafter. Referring to FIG. 11, it can be seenthat the glider member 60 of the clamp assembly 126 comprises agenerally inverted, U-shaped profile with a top wall portion 64 andfirst and second opposed wall portions 66 a, 66 b extending downwardlyfrom the top wall portion 64. The top wall portion 64 comprises afastener aperture 62 disposed centrally therein for receiving the shaftof the threaded fastener member 38. In FIG. 11, it can be seen that theinner surfaces of each of the first and second opposed wall portions 66a, 66 b comprises a plurality of elongate protrusions or teeth 68 thatare each spaced apart from one another by respective elongate grooves70. The set of teeth 68 on each of the inner surfaces of the opposedwall portions 66 a, 66 b are designed to engage with respective teeth110 on opposed upstanding wall portions 104 a, 104 b of the base member90. The glider member 60 may be elastically deformable such that it iscapable of snapping into place on the top of the base member 90. Topermit horizontal adjustability, the glider member 60 is capable ofbeing slid along the length of the base member 90. And, to permitvertical adjustability, the glider member 60 is capable of being movedup and down along a vertical height of the upstanding wall portions 104a, 104 b of the base member 90 and selectively engaging certain ones ofthe teeth 68, 110 with one another.

With reference to FIG. 4, it can be seen that, in the illustrativeembodiment, the clamp assembly 126 is further provided with a serratedwasher 54 disposed between the lower clamp member 20 and the glidermember 60. In FIG. 10, it can be seen that the serrated washer 54includes an annular body portion 56 with a plurality ofdiagonally-oriented teeth 58 extending radially outward from the annularbody portion 56. The diagonally-oriented teeth 58 of the serrated washer54 are designed to cut into the adjacent surfaces of the lower clampmember 20 and the glider member 60 so as resist a rotation of the lowerclamp member 20 relative to the glider member 60. The serrated washer 54with the diagonally-oriented teeth 58 is also used to electrically bondthe lower clamp member 20 to the glider member 60.

Now, referring to FIGS. 1, 2, 14, and 15, it can be seen that theillustrative embodiment of the base assembly 128 generally includes anupstanding base member 90 and a lower flashing member 118. As best shownin the assembled views of FIGS. 2 and 14, the upstanding base member 90is connected to the lower flashing member 118 by a threaded fastenermember 80. In the illustrated embodiment, the threaded fastener member80 is in the form of a structural mounting bolt with a head portion 82and a threaded shaft portion (see FIG. 16). In the illustratedembodiment, each support surface attachment device 100 is secured to arespective one of the roof rafters of a building by means of astructural mounting bolt 80 (e.g., refer to FIG. 1). In one or moreembodiments, the structural mounting bolt or screw 80 may beself-drilling so as not to require any predrilled holes in the roof.

Turning to FIG. 18, the upstanding base member 90 of the base assembly128 will now be described. As shown in this figure, the upstanding basemember 90 generally comprises a base portion with first and secondopposed base flange portions 94 a, 94 b and an elevated shelf portion98. Two opposed upstanding wall portions 104 a, 104 b extend upwardlyfrom the base portion of the base member 90. In FIG. 18, it can be seenthat each of the opposed base flange portions 94 a, 94 b comprises aplurality of fastener apertures 96 arranged in a substantially linearconfiguration along the length thereof. When it is desired to mount theupstanding base member 90 directly to the roof deck, rather than a roofrafter, the base member 90 is secured to the roof deck using fastenersdisposed in the fastener apertures 96. The base portion of the basemember 90 comprises a centrally disposed aperture 92 for accommodatingthe raised portion 122 of the flashing member 118 passing therethrough.The elevated shelf portion 98 of the base portion of the base member 90comprises a fastener aperture 102 disposed therethrough foraccommodating the shaft of the threaded fastener member 80. In FIG. 18,it can be seen that the outer surfaces of each of the first and secondopposed upstanding wall portions 104 a, 104 b comprises a plurality ofelongate protrusions or teeth 110 that are each spaced apart from oneanother by respective elongate grooves 112. As described above, the setof teeth 110 on each of the outer surfaces of the opposed wall portions104 a, 104 b are designed to engage with the respective teeth 68 on theopposed wall portions 66 a, 66 b of the glider member 60. Also, as shownin FIG. 18, the opposed wall portions 104 a, 104 b of the base member 90cooperate to define an upper elongate slot 106 that accommodates theshaft of the threaded fastener member 38 passing therethrough. Also,each of the opposed wall portions 104 a, 104 b comprises a downturnedlip portion 108 that is received within a respective one of the elongategrooves 76 disposed in the top surface of the strut nut 72.

With reference primarily to FIG. 20, the flashing member 118 of the baseassembly 128 will now be explained. The flashing member 118 helps tomaintain the integrity of the building roof by preventing roof leaks. InFIG. 20, it can be seen that the flashing member 118 generally comprisesa generally planar body portion 120 and a raised portion or projection122 that extends upwardly from the generally planar body portion 120 ina generally vertical direction. As best shown in the perspective view ofFIG. 20, the raised portion or projection 122 is offset with respect tothe center of the generally planar body portion 120 (i.e., the raisedportion or projection 122 is disposed to the side of the central pointof the generally planar body portion 120). In FIG. 20, it can be seenthat the raised portion or projection 122 includes a centrally disposedfastener aperture 124 for receiving the shaft of the structural mountingbolt 80 therein. Advantageously, the raised nature of the protrusion orprojection 122 above the remainder of the generally planar body portion120 of the flashing member 118 substantially prevents any precipitation(i.e., rain water) from entering the structure of the building roofthrough the fastener aperture 124. In the assembled state of the supportsurface attachment device 100, in order to further prevent any leaksthrough the aperture 124 of the flashing member 118, a lower sealingwasher 114 (see FIGS. 15 and 19) is provided on the top of the raisedportion or projection 122 of the flashing member 118. The lower sealingwasher 114 comprises a fastener aperture 116 disposed therein foraccommodating the shaft of the structural mounting bolt 80. The lowersealing washer 114 is sandwiched between the raised portion orprojection 122 of the flashing member 118 and the bottom surface of theelevated shelf portion 98 of the base member 90 when the base member 90is disposed on top of the flashing member 118 in the assembled state ofthe support surface attachment device 100. In addition, in the assembledstate, an upper sealing washer 84 is disposed between the bottom surfaceof the head portion 82 of the bolt 80 and the top surface of theelevated shelf portion 98 of the base member 90 to additionally preventany leaks through the roof. As shown in FIG. 17, the upper sealingwasher 84 comprises a flanged top portion 88 with a fastener aperture 86disposed through the center thereof for accommodating the shaft of thestructural mounting bolt 80. In the assembled state of the supportsurface attachment device 100, the upper sealing washer 84 is sandwichedbetween the bottom surface of the bolt head portion 82 and the topsurface of the elevated shelf portion 98 of the base member 90. In oneexemplary embodiment, the flashing member 118 may be formed from stampedmetal, and the upper and lower sealing washers 84, 114 may be formedfrom a suitable plastic or rubber, such as ethylene propylene dienemonomer (EPDM).

Advantageously, the design of the flashing member 118 illustrated inFIGS. 14, 15, and 20 results in superior waterproofing because its waterseal is elevated above the roof surface (i.e., at the top of the raisedportion or projection 122) so that the integrity of the flashingwaterproofing is maintained even if the sealing washer 114 would fail.Also, because the flashing member 118 may be formed by stamping, itsmanufacturing costs are inexpensive. In addition, the configuration ofthe flashing member 118 allows adjacent flashing members 118 to bereadily stacked for compact shipping.

Now, with reference to FIGS. 21-25, it can be seen that the illustrativeembodiment of the coupling device or assembly 130 generally includes anupper coupling member 140 secured to a lower coupling member 150. Asbest shown in the assembled view of FIG. 21 and the exploded view ofFIG. 22, the upper coupling member 140 and the lower coupling member 150are connected to one another by means of one or more threaded fastenermembers 168 (e.g., two (2) threaded fastener members 168) and one ormore respective captive nuts 170 (e.g., two (2) captive nuts 170, onefor each threaded fastener member 168). In the illustrated embodiment,each threaded fastener member 168 is in the form of a bolt with a headportion having a serrated flange (e.g., refer to FIG. 21). As describedabove for the bolts 38, the serrations in the lower surface of the bolthead flange of each threaded fastener member 168 are configured tointerferingly engage with the top surface of the upper coupling member140 (i.e., “dig into” the top surface of the upper coupling member 140).The external threads on the shaft of each threaded fastener member 168are configured to threadingly engage with the internal threads in thethreaded aperture 172 of the captive nut 170 (see FIG. 25).

Turning to FIG. 23, the structure of the upper coupling member 140 willbe described. As shown in this figure, the upper coupling member 140generally includes a base portion 142 that is attached to the bottomsurface of a flange portion 144 a, 144 b at approximately a 90 degreeangle. In this figure, it can be seen that one side surface of baseportion 142 comprises a plurality of elongate protrusions or teeth 148that are each spaced apart from one another by respective elongategrooves 149. As will be described hereinafter, the plurality of elongateprotrusions or teeth 148 matingly engage with elongate protrusions orteeth 160 disposed on the first opposed wall portion 154 a of theupstanding middle portion 152 of the lower coupling member 150.Referring again to FIG. 23, it can be seen that the flange portion 144a, 144 b of the upper coupling member 140 further comprises a pluralityof fastener apertures 145 for receiving respective threaded fastenermembers 168 and a downwardly protruding member 147 that forms a backsurface against which a photovoltaic module rests when disposed in thecoupling assembly 130. Also, as shown in FIG. 23, each of the flangeportions 144 a, 144 b includes an elongate groove 146 disposed in thebottom surface thereof. Each of the elongate grooves 146 is configuredto receive a trough portion 48 of a respective bonding clip 42 (seeFIGS. 7 and 22) that provides integrated grounding for the photovoltaicmodule installation. The trough portion 48 of each respective bondingclip 42 is received within its respective elongate groove 146 in apress-fit or interference-fit type mounting arrangement.

Next, turning to FIG. 24, the structure of the lower coupling member 150will be explained. With reference to this figure, it can be seen thatthe lower coupling member 150 generally includes an upstanding middleportion 152 with first and second ledge portions 156, 158 extendingoutwardly from the upstanding middle portion 152. In FIG. 24, it can beseen that the upstanding middle portion 152 of the lower coupling member150 comprises spaced-apart lower fastener apertures disposed in a bottomwall portion thereof, and spaced-apart upper fastener apertures 155disposed in a top wall portion 153 thereof. Each of these aperturesreceives a respective shaft of a respective threaded fastener member168. The bottom wall portion and the top wall portion 153 of theupstanding middle portion 152 of the lower coupling member 150 areconnected to one another by first and second opposed wall portions 154a, 154 b. As shown in FIG. 24, the first opposed wall portion 154 acomprises a plurality of elongate protrusions or teeth 160 that are eachspaced apart from one another by respective elongate grooves 162. Asexplained above, the elongate teeth 160 of the first opposed wallportion 154 a engage with the elongate teeth 148 of the base portion 142of the upper coupling member 140. Referring again to FIG. 24, it can beseen that the second opposed wall portion 154 b comprises a plurality ofelongate hook-shaped protrusions or teeth 164 that are each spaced apartfrom one another by respective elongate grooves 166. The hook-shapedteeth 164 on the second opposed wall portion 154 b are configured toengage with a wind deflector and/or a mounting skirt for deflecting windup and over the photovoltaic array and/or improving the aesthetics ofthe array, as will be described hereinafter. Each of the first andsecond ledge portions 156, 158 of the lower coupling member 150 isconfigured to accommodate a photovoltaic module frame member restingthereon.

With reference to FIGS. 26-28, a skirt member 174 of the photovoltaicmounting system will be described. Initially, referring to theperspective view of FIG. 26, it can be seen that the skirt member 174 isconfigured to be located on the southernmost edge of the array of PVmodules. The skirt member 174 is supported by spaced-apart supportsurface attachment devices 100. In particular, as shown in the side viewof FIG. 27, the skirt member 174 engages with the upper clamp member 10and the lower clamp member 20 of the clamp assembly 126 of the supportsurface attachment device 100. As shown in this figure, the skirt member174 is clampingly engaged by the upper clamp member 10, and isadditionally engaged by the hook-shaped teeth 34 of the lower clampmember 20.

Referring again to FIGS. 27 and 28, the engagement between the skirtmember 174 and the lower clamp member 20 will be explained in moredetail. As shown in the perspective view of FIG. 28, a backside of theskirt member 174 comprises a plurality of elongate hook-shapedprotrusions or teeth 176 that are each spaced apart from one another byrespective elongate grooves 178. With reference to the side view of FIG.27, it can be seen that at least some of the hook-shaped protrusions orteeth 176 of the skirt member 174 matingly engage with at least some ofthe hook-shaped protrusions or teeth 34 on the lower clamp member 20.This engagement between the hook-shaped protrusions or teeth 34, 176enables the skirt member 174 to be securely supported on the clampassembly 126. The hook-shaped protrusions or teeth 164 on the lowercoupling member 150 engage with the hook-shaped protrusions or teeth 176of the skirt member 174 in a manner that is generally the same as thatof the hook-shaped protrusions or teeth 34 on the lower clamp member 20.Advantageously, the hook-shaped protrusions or teeth 176, 34 on theskirt member 174 and the lower clamp member 20, respectively, allows theskirt member 174 to be mounted at various heights relative to the lowerclamp member 20 so that the skirt member 174 is capable of matching PVmodules having more than one height. This is important because the skirtmember 174 sets the gap size of the clamp assembly 126 and the couplingassembly 130 on the south row of the PV array to accept the first row ofPV modules.

In the perspective view of FIG. 26, it can be seen that the skirt member174 is configured to cover the exposed downhill edge of the array of PVmodules (only one skirt member 174 is shown in FIG. 26). Because theskirt member(s) 174 closes out the south row of PV modules, it improvesthe aesthetics of the completed photovoltaic array. No clamps orhardware is seen from ground. Airflow around the array is permitted. Inone exemplary embodiment, the skirt member 174 may be formed fromaluminum. In another exemplary embodiment, the skirt member 174 may beformed from a suitable polymer.

A second illustrative embodiment of a support surface attachment deviceis seen generally at 100′ in FIG. 29. Referring to this figure, it canbe seen that, in some respects, the second illustrative embodiment issimilar to that of the first embodiment of the support surfaceattachment device 100. Moreover, some elements are common to both suchembodiments. For the sake of brevity, the elements that the secondembodiment of the support surface attachment device has in common withthe first embodiment will not be discussed in detail because thesecomponents have already been described above.

Initially, with reference to FIGS. 43 and 44, it can be seen that thesecond embodiment of the clamp assembly 126′ generally includes an upperclamp member 10′, a lower clamp member 20′, and a glider member 60′. Asbest shown in the assembled view of FIG. 43, the upper clamp member 10′,lower clamp member 20′, and glider member 60′ are connected to oneanother by means of a threaded fastener member 38 and a strut nut 72. Asin the first illustrated embodiment, the threaded fastener member 38 isin the form of a bolt with a head portion having a serrated flange 40(refer to FIG. 5). The strut nut 72 that is used in the secondillustrative embodiment is also the same as that utilized in the firstillustrative embodiment. As shown in the exploded view of FIG. 44, anO-ring 196 is provided on the shaft of the threaded fastener member 38.The O-ring 196 stabilizes the clamp assembly on the glider member 60′prior to installation.

Now, with reference to FIG. 30, the structure of the upper clamp member10′ of the second embodiment will be described. Similar to thatdescribed above for the first embodiment, the upper clamp member 10′generally includes a base portion 12′ that is attached to the bottomsurface of a flange portion 14 a, 14 b at approximately a 90 degreeangle. In this figure, it can be seen that one side surface of baseportion 12′ comprises a pair of elongate protrusions or teeth 18′ thatare each spaced apart from one another by an elongate groove 19′. Aswill be described hereinafter, the pair of elongate protrusions or teeth18′ matingly engage with elongate protrusions or teeth 30′ disposed onthe first opposed wall portion 24 a′ of the upstanding middle portion22′ of the lower clamp member 20′. Referring again to FIG. 30, it can beseen that the flange portion 14 a, 14 b of the upper clamp member 10′further comprises a fastener aperture 15 for receiving the threadedfastener member 38 and a downwardly protruding member 17′ that forms aback surface against which a photovoltaic module rests when disposed inthe clamp assembly 126′. Also, as shown in FIG. 30, each of the flangeportions 14 a, 14 b includes an elongate groove 16′ disposed in thebottom surface thereof. Each of the elongate grooves 16′ is configuredto receive a projection portion 49′ of a respective bonding clip 42′(see FIG. 31) that provides integrated grounding for the photovoltaicmodule installation. The projection portion 49′ of each respectivebonding clip 42′ is received within its respective elongate groove 16′in a press-fit or interference-fit type mounting arrangement. Also, asshown in FIG. 30, the upper clamp member 10′ of the clamp assemblycomprises a pair of downwardly extending lip portions 376, 378 onopposite sides of the flanged top portion 14 a, 14 b of the upper clampmember 10′. The first downwardly extending lip portion 376 is shorterthan the second downwardly extending lip portion 378 so as to facilitatethe one or more photovoltaic modules being pivotably installed into thefirst side of the clamp assembly (i.e., into the side of clamp assemblywith flange portion 14 a). As such, the shorter downwardly extending lipportion 376 does not interfere with the minimum gap needed to allowpivoted north side PV module mounting.

A third illustrative embodiment of the upper clamp member 10″ is shownin FIGS. 45 and 46. The third embodiment of the upper clamp member 10″is similar in most respects to the second embodiment of the upper clampmember 10′ explained above. Like the second embodiment of the upperclamp member 10′, the upper clamp member 10″ in FIGS. 45 and 46generally includes a base portion 12″ that is attached to the bottomsurface of a flange portion 14 a, 14 b at approximately a 90 degreeangle. Although, in FIGS. 45 and 46, it can be seen that the one side ofthe base portion 12″ of the upper clamp member 10″ comprises three (3)elongate protrusions or teeth 18′ that are each spaced apart from oneanother by respective elongate grooves 19″, rather than the pair ofelongate protrusions or teeth 18′ described above for the secondembodiment. Similar to the upper clamp member 10′ of FIG. 30, each ofthe flange portions 14 a, 14 b of the upper clamp member 10″ of FIGS. 45and 46 includes an elongate groove 16″ disposed in the bottom surfacethereof for accommodating a respective bonding clip (e.g., bonding clip42′ in FIG. 31 or bonding clip 42″ in FIG. 47). However, unlike theupper clamp member 10′ of FIG. 30, the downwardly protruding member 17″of the upper clamp member 10″ additionally contains a groove 11 formedin one side thereof for capturing an edge of the bonding clip (e.g.,bonding clip 42′ in FIG. 31 or bonding clip 42″ in FIG. 47), and holdingit in place (refer to FIG. 75).

Additional embodiments of the bonding or grounding clip, which providesintegrated grounding for the photovoltaic modules, are illustrated inFIGS. 31, 47, and 81, respectively. Similar to the bonding clip 42 ofFIG. 7 described above, the bonding clips 42′, 42″ of FIGS. 31 and 47each comprise a plate-like body portion with a plurality of upwardlyprotruding annular members 44′ and a plurality of downwardly protrudingannular members 46′ formed therein. In particular, in the illustrativeembodiments, each of the upwardly protruding annular members 44′ isarranged adjacent to a respective opposite end of the plate-like bodyportion, and the pair of downwardly protruding annular members 46′ aredisposed between the pair of upwardly protruding annular members 44′.The upwardly and downwardly protruding annular members 44′, 46′ are alsogenerally arranged in a staggered, non-aligned configuration on theplate-like body portions of the bonding clips 42′, 42″. As explainedabove for bonding clip 42, the upwardly protruding members 44 aredesigned to pierce the metallic bottom surface of the flange portion 14a, 14 b of the upper clamp member 10′, while the downwardly protrudingannular member 46 is designed to pierce the anodized layer of thephotovoltaic module to provide integrated grounding between thephotovoltaic modules.

Referring to bonding clip 42′ in FIG. 31, it can be seen that aprojection portion 49 is attached to the plate-like body portion of thebonding clip 42′. The projection portion 49 of the bonding clip 42′engages with a selected one of the elongate grooves 16′, 16″ in theupper clamp members 10′, 10″ so as to hold the bonding clip 42′ inplace. The bonding clip 42″ of FIG. 47 also contains a projectionportion 49′ that is attached to the plate-like body portion of thebonding clip 42″. As shown in FIG. 47, the projection portion 49′ of thebonding clip 42″ comprises a pair of spaced-apart bent over tabs 47,47′, wherein each tab 47, 47′ is disposed at an opposite end of theprojection portion 49′. Each of the tabs 47, 47′ engages with a selectedone of the elongate grooves 16′, 16″ in the upper clamp members 10′, 10″in order to hold the bonding clip 42′, 42″ in place in the clampassembly 126′. Also, similar to the bonding clips 42, 42′, 42″, thebonding clip 42′″ of FIG. 81 comprises a plate-like body portion 43 witha plurality of upwardly protruding annular members 44′ and a pluralityof downwardly protruding annular members 46′ formed therein. Theplate-like body portion 43 of the clip 42′″ is not folded over. Like theembodiment of FIGS. 31 and 47, the upwardly and downwardly protrudingannular members 44′, 46′ of the clip 42′″ are arranged in a staggeredconfiguration. However, unlike the preceding embodiments of the bondingclip, the clip attachment portions of the bonding clip 42′″ of FIG. 81comprise a pair of flange members 45, each of which is disposed at anopposite end of the clip body portion 43. When the bonding clip 42′″ isinstalled on an object (e.g., upper clamp members 10′, 10″), a topportion of each of the pair of flange members 45 (i.e., the top fold ofthe flange members 45) remains visible to an installer so that aninstalled condition of the bonding clip 42′″ is capable of beingverified by the installer. Also, advantageously, the flange members 45of the bonding clip 42′″ allow the clip 42′″ to be installed without theneed to fully open the clamp assembly (i.e., the installer only needs toopen the clamp a small amount). In one or more embodiments, the bondingclip 42′″ may be used on the north side of a photovoltaic module row.

Next, turning to FIG. 32, the structure of the second embodiment of thelower clamp member 20′ will be explained. Similar to that describedabove for the lower clamp member 20, it can be seen that the lower clampmember 20′ generally includes an upstanding middle portion 22′ withfirst and second ledge portions 26, 28 extending outwardly from theupstanding middle portion 22′ (refer to FIG. 32). In FIG. 32, it can beseen that the upstanding middle portion 22 of the lower clamp member 20comprises a lower fastener aperture 21 disposed in a bottom wall portionthereof, and an upper fastener aperture 25 disposed in a top wallportion 23′ thereof. Each of these apertures 21, 25 receives the shaftof the threaded fastener member 38. The bottom wall portion and the topwall portion 23′ of the upstanding middle portion 22 of the lower clampmember 20 are connected to one another by first and second opposed wallportions 24 a′, 24 b′. As shown in FIG. 32, the first opposed wallportion 24 a′ comprises a plurality of elongate protrusions or teeth 30′(e.g., with generally wedge-shaped cross-sections) that are each spacedapart from one another by respective elongate grooves 32′. As explainedabove, the elongate teeth 30′ of the first opposed wall portion 24 a′engage with the elongate teeth 18′ of the base portion 12′ of the upperclamp member 10′. Referring again to FIG. 32, it can be seen that thesecond opposed wall portion 24 b′ comprises a plurality of upwardlyinclined elongate protrusions or teeth 34′ that are spaced apart fromone another by elongate grooves 36′ , 37. More particularly, the uppertwo (2) protrusions or teeth 34′ are spaced apart from one another bythe narrow width elongate groove 36′, while the upper two (2)protrusions or teeth 34′ are spaced apart from a bottom protrusion ortooth 34′ disposed near the surface of the second ledge portion 28 by awide elongate groove 37. The upwardly inclined elongate protrusions orteeth 34′ on the second opposed wall portion 24 b′ are configured toengage with a wind deflector and/or a mounting skirt for deflecting windup and over the photovoltaic array and/or improving the aesthetics ofthe array (see e.g., FIG. 72). Advantageously, the upwardly inclinedelongate protrusions or teeth 34′ allow the skirt to be dropped in atthe appropriate height, and once the skirt is secured, the upward facingprotrusions or teeth 34′ resist torsional detachment from the lowerclamp member 20′ (e.g., due to ice expansion on the PV array applying aforce against the skirt). Each of the first and second ledge portions26, 28 of the lower clamp member 20 is configured to accommodate aphotovoltaic module frame member resting thereon. As described above forthe first embodiment of the lower clamp member 20, the second opposedledge 28 of the lower clamp member 20′ is bent slightly upward, or istapered slightly upward at an acute angle, so as to be capable ofperforming the same functionality explained above for the lower clampmember 20. In addition, as shown in FIG. 32, the lower clamp member 20′of the clamp assembly comprises a plurality of ridges 380 disposed on abottom surface thereof. The ridges 380 are configured to increase africtional engagement between the lower clamp member 20′ and the glidermember 60′ so as prevent the upper and lower clamp members 10′, 20′ ofthe clamp assembly from rotating relative to the glider member 60′ whenthe threaded fastener member 38 is tightened by an installer (i.e., theridges 380 increase the resistance to rotation of the clamp assembly onthe glider member 60′).

In the illustrated embodiment, one or more of the teeth or serrations30′ on the lower clamp member 20′ are configured to engage one or moreof the teeth or serrations 18′ on the upper clamp member 10′ when thethreaded fastener 38 is being tightened so as to maintain a minimum gapbetween the upper clamp member 10′ and the lower clamp member 20′ forreceiving one or more photovoltaic module frames of one or morephotovoltaic modules when the one or more photovoltaic modules arepivotably installed into a first side (e.g., north side) of the clampassembly. In an exemplary embodiment, the clamp assembly 10′, 20′ isdesigned to accept 32, 33, 35, 40, 45, and 50 millimeter (mm) PVmodules. As such, in the exemplary embodiment, the serrations 18′, 30′on the upper and lower clamp members 10′, 20′ are positioned to engageat the above mentioned dimensions. As the threaded fastener 38 of theclamp is tightened, the downhill side of the clamp contacts a module(e.g., the south side of the clamp), and a torque is applied to theupper clamp member 10′ engaging the teeth. This allows the uphill sideof the clamp (e.g., the north side of the clamp), to remain open,allowing the next module to slide in from above, and to be pivotedmounted in place.

In order to maintain a predetermined spacing distance between the upperand lower clamp members 10′, 20′ during PV module installation, a leafspring member 186 is provided between the clamp members 10′, 20′ (referto FIGS. 43 and 44). In an exemplary embodiment, the leaf spring member186 may be Z-shaped. That is, as best shown in FIG. 43, the leaf springmember 186 is disposed between the top wall portion 23′ of the lowerclamp member 20′ and the bottom surface of the flange portion 14 a, 14 bof the upper clamp member 10′. During the installation of the PV modulesin the PV array, the spring member 186 holds the upper clamp member 10′in place above the lower clamp member 20′ so that a PV module can beinserted between the two (2) clamp members 10′, 20′. Without the use ofthe spring member 186, the flange 14 a, 14 b of the upper clamp member10′ would tend to just rest on the top of the lower clamp member 20′,thereby making it very difficult to insert between the two (2) clampmembers 10′, 20′. In addition, the use of the spring member 186 in theclamp assembly 126′ allows the fastener member 38 to be tightened sothat the strut nut 72 engages the base and secures the clamp to the base90′ without the clamp being compressed.

Turning to FIG. 73, it can be seen that the leaf spring member 186 ofthe clamp assembly 126′ comprises bottom and top leg portions 188, 192,which are connected to one another by a middle diagonal leg portion 190.Each of the leg portions 188, 190, 192 is provided with a respectivefastener aperture 194 disposed therethrough for accommodating the shaftof the threaded fastener member 38. An alternative embodiment of theleaf spring member 186′ is depicted in FIG. 74. Like the spring member186, the leaf spring member 186′ of FIG. 74 comprises bottom and top legportions 188′, 192′, which are connected to one another by a middlediagonal leg portion 190′. However, it can be seen that the geometry ofthe leg portions 188′, 190′, 192′ of the spring member 186′ of FIG. 74are slightly different than the leg portions 188, 190, 192 of the springmember 186 (e.g., the outer ends of the bottom and top leg portions188′, 192′ are not bent like the bottom and top leg portions 188, 192 ofthe FIG. 73 embodiment). Also, similar to the spring member 186, each ofthe leg portions 188, 190, 192 of the spring member 186′ in FIG. 74 isprovided with a respective fastener aperture 194′ disposed therethroughfor accommodating the shaft of the threaded fastener member 38. However,it can be seen that the fastener apertures 194′ are generallyoval-shaped, rather than being circular as in FIG. 73.

As best shown in FIG. 43, the lower clamp member 20′ is positioned abovea glider member 60′ that is configured to be adjustably disposed on theupstanding base member 90′ in both a horizontal and vertical direction,similar to that explained above for the glider member 60. Referring toFIG. 33, like the glider member 60 described above, it can be seen thatthe glider member 60′ of the clamp assembly 126′ comprises a generallyinverted, U-shaped profile with a top wall portion 64′ and first andsecond opposed wall portions 66 a′, 66 b′ extending downwardly from thetop wall portion 64′. The top wall portion 64′ comprises a fasteneraperture 62 disposed centrally therein for receiving the shaft of thethreaded fastener member 38. In FIG. 33, it can be seen that the innersurfaces of each of the first and second opposed wall portions 66 a′, 66b′ comprises a pair of elongate protrusions or teeth 68′ that are spacedapart from one another by a respective elongate groove 70′. The pair ofteeth 68′ on each of the inner surfaces of the opposed wall portions 66a′, 66 b′ are designed to engage with respective teeth 110 on opposedupstanding wall portions 104 a′, 104 b′ of the base member 90′. Theglider member 60′ may be slid into place on the top of the base member90′ by engaging its teeth 68′ with the teeth 110 of the base member 90′.To permit horizontal adjustability, the glider member 60′ is capable ofbeing slid along the length of the base member 90′. And, to permitvertical adjustability, the glider member 60′ is capable of beingadjusted placed along a vertical height of the upstanding wall portions104 a′, 104 b′ of the base member 90′ by selectively engaging certainones of the teeth 68′ on the glider member 60′ with certain ones of thegrooves 112 on the base member 90′, and the groove 70′ on the glidermember 60′ with a certain one of the teeth 110 on the base member 90′.

As shown in FIG. 33, the outer sides of the first and second opposedwall portions 66 a′, 66 b′ of the glider member 60′ are provided with aplurality of generally parallel, visual indicator grooves 61 formedtherein (e.g., three (3) visual indicator grooves 61). During theinstallation of the PV modules, the visual indicator grooves 61 operateas visual indicating bands for positioning the clamp assembly 126′ atits desired height (i.e., the visual indicator grooves 61 enable thedesired height of the clamp assembly 126′ relative to the base member90′ to be more easily obtained by the installer during the PV moduleinstallation process). Also, referring again to FIG. 33, it can be seenthat opposed protrusions 63 may be provided at the top of the glidermember 60′ for holding a chalk line (e.g., a string) in place that isused for the alignment of the PV module row on the support surface(e.g., roof). In an illustrative embodiment, the chalk line (e.g., astring) may be received within the topmost one of the grooves 61, andthe lower two (2) grooves 61 may be used as visual aid indicatorsshowing the height of the glider member 60′ on the upstanding basemember 90′ (i.e., corresponding to the grooves 61).

Now, referring to FIGS. 29 and 34, it can be seen that the secondillustrative embodiment of the base assembly 128′ generally includes anupstanding base member 90′ and a lower flashing member 118′. As bestshown in the assembled view of FIG. 34, the upstanding base member 90′is connected to the lower flashing member 118′ by a threaded fastenermember 80. As described above for the first illustrated embodiment, thethreaded fastener member 80 of the second embodiment is in the form of astructural mounting bolt with a head portion 82 and a threaded shaftportion (see FIG. 16). In the illustrated embodiment, each supportsurface attachment device 100′ is secured to a respective one of theroof rafters of a building by means of a structural mounting bolt 80(e.g., refer to FIG. 29).

Turning to FIG. 35, the upstanding base member 90′ of the base assembly128′ will now be described. As shown in this figure, the upstanding basemember 90′ generally comprises a base portion with first and secondopposed base flange portions 94 a, 94 b and an elevated shelf portion98′. Unlike the first embodiment of the upstanding base member 90′, theelevated shelf portion 98′ of the upstanding base member 90′ does notcomprise any recesses formed therein. Rather, the elevated shelf portion98′ is a generally planar plate that extends between the two (2) opposedupstanding wall portions 104 a′, 104 b′. In FIG. 35, it can be seen thatthe opposed upstanding wall portions 104 a′, 104 b′ extend upwardly fromthe base portion of the base member 90′. Also, with reference to FIG.35, it can be seen that each of the opposed base flange portions 94 a,94 b comprises a plurality of fastener apertures 96 arranged in asubstantially linear configuration along the length thereof. When it isdesired to mount the upstanding base member 90′ directly to the roofdeck, rather than a roof rafter, the base member 90′ is secured to theroof deck using fasteners disposed in the fastener apertures 96. Thebase portion of the base member 90′ comprises a centrally disposedaperture 92 for accommodating the raised portion 122′ of the flashingmember 118′ passing therethrough. The elevated shelf portion 98′ of thebase portion of the base member 90′ comprises a flashing/fasteneraperture 102 disposed therethrough for accommodating the top annularportion 125 of the flashing raised portion 122′ and the shaft of thethreaded fastener member 80 disposed within the flashing annular portion125 (e.g., see the sectional view in FIG. 78). In FIG. 35, it can beseen that the outer surfaces of each of the first and second opposedupstanding wall portions 104 a, 104 b comprises a plurality of elongateprotrusions or teeth 110 that are each spaced apart from one another byrespective elongate grooves 112. As described above, the set of teeth110 on each of the outer surfaces of the opposed wall portions 104 a,104 b are designed to engage with the respective teeth 68′ on theopposed wall portions 66 a′, 66 b′ of the glider member 60′. Also, asshown in FIG. 35, the opposed wall portions 104 a′, 104 b′ of the basemember 90′ cooperate to define an upper elongate slot 106 thataccommodates the shaft of the threaded fastener member 38 passingtherethrough. Also, each of the opposed wall portions 104 a′, 104 b′comprises a downturned lip portion 108 that is received within arespective one of the elongate grooves 76 disposed in the top surface ofthe strut nut 72. Turning to FIG. 34, it can be seen that a bottomsurface of the upstanding base member 90′ may include a plurality ofridges 382 disposed thereon. The ridges 382 are configured to increase africtional engagement between the upstanding base member 90′ and theflashing member 118′ so as prevent the upstanding base member 90′ fromrotating relative to the flashing member 118′ when a base fastenermember 80 is tightened by an installer (i.e., the ridges 382 slightlydeform the flashing member 118′ when the base member 90′ is tightenedagainst the flashing so as to resist the turning of the base member 90′relative to the flashing member 118′). Also, the ridges 382 disposed onthe bottom surface of the upstanding base member 90′ are additionallyconfigured to capture and hold sealing tape (e.g., butyl tape) when theupstanding base member 90′ is mounted directly against the supportsurface (e.g., directly against a roof deck in deck-mountedinstallation). Referring again to FIG. 34, it can be seen that a topsurface of the upstanding base member 90′ may include a plurality ofvisual installation guide marks 384 configured to facilitate aninstallation of one or more rows of the one or more photovoltaic modules(e.g., to facilitate the accurate setting of the south row in the PVmodule array).

With reference primarily to FIG. 37, the flashing member 118′ of thebase assembly 128′ will now be explained Like the flashing member 118described above, the flashing member 118′ helps to maintain theintegrity of the building roof by preventing roof leaks. In FIG. 37, itcan be seen that the flashing member 118′ generally comprises agenerally planar body portion 120′ and a raised portion or projection122′ that extends upwardly from the generally planar body portion 120′in a generally vertical direction. As best shown in the perspective viewof FIG. 37, the raised portion or projection 122′ is offset with respectto the center of the generally planar body portion 120′ (i.e., theraised portion or projection 122′ is disposed to the side of the centralpoint of the generally planar body portion 120′). In FIG. 37, it can beseen that the raised portion or projection 122′ includes a centrallydisposed fastener aperture 124 for receiving the shaft of the structuralmounting bolt 80 therein. As shown in FIG. 37, the flashing raisedportion 122′ further includes a generally horizontal ledge portion 123that extends radially inward towards the fastener aperture 124, andannular collar portion 125 that extends upwardly from the ledge portion123 of the flashing raised portion 122′. As shown in the sectional viewof FIG. 78, the bottom surface of the elevated shelf portion 98′ of thebase member 90′ is disposed adjacent to the flashing ledge portion 123in the assembled state of the base assembly 128′, while the upstanding,annular collar portion 125 of the flashing raised portion 122′ extendsthrough the flashing/fastener aperture 102 in the base shelf portion 98′to help maintain the integrity of the building roof. As described abovefor the flashing member 118, the raised nature of the protrusion orprojection 122′ above the remainder of the generally planar body portion120′ of the flashing member 118′ substantially prevents anyprecipitation (i.e., rain water) from entering the structure of thebuilding roof through the fastener aperture 124. In the assembled stateof the support surface attachment device 100′, in order to furtherprevent any leaks through the aperture 124 of the flashing member 118′,an upper sealing washer 84′ (see FIGS. 76-78) is provided on the top ofthe annular collar portion 125 of the flashing raised portion 122′ ofthe flashing member 118′.

In the illustrated embodiment of FIG. 78, when the upstanding basemember 90′ of the base assembly is assembled with the flashing member118′, a top surface of the circumferential ledge portion 123 of theraised portion 122′ of the flashing member 118′ is configured toregulate a height of the top annular portion 125 of the raised portion122′ of the flashing member 118′ so that a top rim of the top annularportion 125 of the raised portion 122′ does not protrude substantiallyabove a top surface of the elevated shelf 98′ of the upstanding basemember 90′. That is, in the illustrative embodiment, when the basemember 90′ contacts the flashing member 118′, the top annular portion125 protrudes a small predetermined distance above the top surface ofthe elevated shelf 98′. The interface between the base member 90′ andthe flashing member 118′ dictates the height of the flashing protrudingabove the base web or shelf 98′, and it prevents the over compression ofthe sealing member 89 of the sealing washer 84′. The large radius at thebase of the raised portion 122′ of the flashing member 118′ is designedto flex to accommodate various roof conditions further increasing theuniformity of sealing interface.

With combined reference to FIGS. 76-78, it can be seen that the uppersealing washer 84′ comprises a fastener aperture 86 disposedtherethrough for accommodating the shaft of the structural mounting bolt80. The upper sealing washer 84′ is disposed between the bottom surfaceof the head portion 82 of the bolt 80 and the top surface of theelevated shelf portion 98′ of the base member 90′ to additionallyprevent any leaks through the roof. As shown in FIGS. 76-78, the uppersealing washer 84′ comprises a top outer portion 87 and a bottom innerportion 89 disposed within, and underneath the top outer portion 87. Inone exemplary embodiment, the top outer portion 87 of the upper sealingwasher 84′ may be formed from stainless steel and the bottom innerportion 89 of the upper sealing washer 84′ may be formed from a suitableplastic or rubber, such as ethylene propylene diene monomer (EPDM). Inone or more embodiments, the upper sealing washer 84′ is a cup washerthat is configured to control the type and/or amount of washercompression so that, when compressed by the tightening of the bolt 80,the EPDM inner portion 89 of the washer 84′ will not enter into theannular gap between the outer surface of the flashing annular collarportion 125 and the inner circular wall of the flashing/fasteneraperture 102 in the base shelf portion 98′ of the base member 90′. Thatis, the compression of the upper sealing washer 84′ is regulated so asto seal around the outer sidewall of the flashing annular collar portion125, but not enter the annular gap between the flashing annular collarportion 125 and the inner circular wall of the flashing/fasteneraperture 102, thereby creating an efficient waterproof seal for the baseassembly 128′.

As best shown in the illustrative embodiment of FIG. 77, the bottominner portion 89 of the upper sealing washer 84′ may comprise a steppedand/or upwardly tapered bottom surface 85 so as to tightly engage thetop rim of the flashing annular collar portion 125, and to prevent theEPDM inner portion 89 of the washer 84′ from entering the fasteneraperture 124 in the flashing member 118′ (see FIGS. 37 and 78).

Advantageously, the design of the flashing member 118′ illustrated inFIGS. 34, 37, and 78 results in superior waterproofing because its waterseal is elevated above the roof surface (i.e., at the top of the raisedportion or projection 122′) so that the integrity of the flashingwaterproofing is maintained. Also, because the flashing member 118′ maybe formed by stamping, its manufacturing costs are inexpensive. Inaddition, the configuration of the flashing member 118′ allows adjacentflashing members 118′ to be readily stacked for compact shipping.

With reference to FIG. 36, in the illustrative embodiment, the baseassembly 128′ may be further provided with a serrated washer 54′disposed between the ledge portion 123 of the flashing raised portion122′ and the bottom surface of the elevated shelf portion 98′ of thebase member 90′ when the base member 90′ is disposed on top of theflashing member 118′ in the assembled state of the support surfaceattachment device 100′. The serrated washer 54′ is used for electricallygrounding the base assembly 128′ by creating a current path between thebase member 90′ and the flashing member 118′. In FIG. 36, it can be seenthat the serrated washer 54′ includes an outer annular body portion 56′with a plurality of diagonally-oriented teeth 58′ extending radiallyinward from the outer annular body portion 56′. The diagonally-orientedteeth 58′ of the serrated washer 54′ are designed to cut into theadjacent surfaces of the base member 90′ and the flashing member 118′ soas to provide an electrical grounding path between the two components sothat the two components are electrically bonded to one another.

Now, with reference to FIGS. 40-42, it can be seen that, like thecoupling assembly 130 described above, the second illustrativeembodiment of the coupling assembly 130′ generally includes an uppercoupling member 140′ secured to a lower coupling member 150′. As bestshown in the assembled view of FIG. 40, the upper coupling member 140′and the lower coupling member 150′ are connected to one another by meansof one or more threaded fastener members 168 (e.g., two (2) threadedfastener members 168) and one or more respective captive nuts 170 (e.g.,two (2) captive nuts 170, one for each threaded fastener member 168). Inthe illustrated embodiment, each threaded fastener member 168 is in theform of a bolt with a head portion having a serrated flange (e.g., referto FIG. 40).

Turning to FIG. 41, the structure of the upper coupling member 140′ willbe described. As shown in this figure, the upper coupling member 140′generally includes a base portion 142′ that is attached to the bottomsurface of a flange portion 144 a, 144 b at approximately a 90 degreeangle. In this figure, it can be seen that one side surface of baseportion 142′ comprises a plurality of elongate protrusions or teeth 148′that are each spaced apart from one another by respective elongategrooves 149′. As will be described hereinafter, the plurality ofelongate protrusions or teeth 148′ matingly engage with elongateprotrusions or teeth 160′ disposed on the first opposed wall portion 154a′ of the upstanding middle portion 152′ of the lower coupling member150′. Referring again to FIG. 41, it can be seen that the flange portion144 a, 144 b of the upper coupling member 140 further comprises aplurality of fastener apertures 143, 145 for receiving respectivethreaded fastener members 168 and a downwardly protruding member 147′that forms a back surface against which a photovoltaic module rests whendisposed in the coupling assembly 130. In the illustrative embodiment ofFIG. 41, it can be seen that each of fastener apertures 143 has agenerally oval shape, while the fastener apertures 145 has a generallycircular shape. Also, as shown in FIG. 41, each of the flange portions144 a, 144 b includes an elongate groove 146′ disposed in the bottomsurface thereof. Each of the elongate grooves 146′ is configured toreceive one or more projection portions 49, 49′ of the bonding clip 42′,42″ that provides integrated grounding for the photovoltaic moduleinstallation. The projection portion 49, 49′ of each bonding clip 42′,42″ is received within its respective elongate groove 146′ in apress-fit or interference-fit type mounting arrangement. Turning to FIG.41, it can be seen that a top surface of flanged portion 144 a, 144 b ofthe upper coupling member 140′ may include a plurality of visualinstallation guide marks 386 to indicate locational limits of mountingthe one or more photovoltaic modules within the coupling device 130′(i.e., location limits of mounting against the PV modules).

Next, turning to FIG. 42, the structure of the lower coupling member150′ will be explained. With reference to this figure, it can be seenthat the lower coupling member 150′ generally includes an upstandingmiddle portion 152′ with first and second ledge portions 156, 158extending outwardly from the upstanding middle portion 152′. In FIG. 42,it can be seen that the upstanding middle portion 152′ of the lowercoupling member 150′ comprises spaced-apart lower fastener aperturesdisposed in a bottom wall portion thereof, and spaced-apart upperfastener apertures 155 disposed in a top wall portion 153′ thereof. Eachof these apertures receives a respective shaft of a respective threadedfastener member 168. The bottom wall portion and the top wall portion153′ of the upstanding middle portion 152′ of the lower coupling member150′ are connected to one another by first and second opposed wallportions 154 a′, 154 b′. As shown in FIG. 42, the first opposed wallportion 154 a′ comprises a plurality of elongate protrusions or teeth160′ that are each spaced apart from one another by respective elongategrooves 162′. As explained above, the elongate teeth 160′ of the firstopposed wall portion 154 a′ engage with the elongate teeth 148′ of thebase portion 142′ of the upper coupling member 140′. Referring again toFIG. 42, it can be seen that the second opposed wall portion 154 b′comprises a plurality of elongate upwardly inclined protrusions or teeth164′, one or more elongate downwardly inclined protrusions or teeth 165,and one or more elongate V-shaped protrusions or teeth 167. As shown inFIG. 42, the protrusions or teeth 164′, 165, 167 are spaced apart fromone another by elongate grooves 166′. The protrusions or teeth 164′,165, 167 on the second opposed wall portion 154 b′ of the base portion142′ of the lower coupling member 150′ are configured to engage with awind deflector and/or a mounting skirt for deflecting wind up and overthe photovoltaic array and/or improving the aesthetics of the array, aswill be described hereinafter. Each of the first and second ledgeportions 156, 158 of the lower coupling member 150 is configured toaccommodate a photovoltaic module frame member resting thereon. As shownin FIG. 42, the protrusions or teeth 164′, 165, 167 of the lowercoupling member 150′ comprise a plurality of mating protrusions or teeth164′, 165, 167 disposed in alternating upward and downward orientationsso that the coupling device 130′ is capable of remaining in engagementwith the skirt member 174″ prior to the threaded fastening members 168being tightened by an installer. For example, in one or moreembodiments, the coupling device 130′ is initially slid on the skirtmember 174″ by the installer, and once slid on, the coupling device 130′will stay in place and the installer can take his or her hand off thecoupling device 130′. The alternating protrusions or teeth 164′, 165,167 of the lower coupling member 150′ allow the coupling device 130′ tostay in place on the skirt member 174″.

In the illustrated embodiment, one or more of the teeth or serrations160′ on the lower coupling member 150′ are configured to engage one ormore of the teeth or serrations 148′ on the upper coupling member 140′when the threaded fasteners 168 are being tightened so as to maintain aminimum gap between the upper coupling member 140′ and the lowercoupling member 150′ for receiving one or more photovoltaic moduleframes of one or more photovoltaic modules when the one or morephotovoltaic modules are pivotably installed into a first side (e.g.,north side) of the coupling assembly 130′. In an exemplary embodiment,the coupling assembly 130′ is designed to accept 32, 33, 35, 40, 45, and50 millimeter (mm) PV modules. As such, in the exemplary embodiment, theserrations 148′, 160′ on the upper and lower coupling members 140′, 150′are positioned to engage at the above mentioned dimensions. As thethreaded fasteners 168 of the coupling are tightened, the downhill sideof the coupling contacts a module (e.g., the south side of thecoupling), and a torque is applied to the upper coupling member 140′engaging the teeth. This allows the uphill side of the coupling (e.g.,the north side of the coupling), to remain open, allowing the nextmodule to slide in from above, and to be pivoted mounted in place.

With reference to FIGS. 38, 39, and 72, additional embodiments of thelower skirt member 174′, 174″ of the photovoltaic mounting system willbe described. Initially, referring to the end view of FIG. 72, it can beseen that the skirt member 174′, 174″ is configured to be located on thesouthernmost edge of the array of PV modules. The skirt member 174′,174″ is supported by spaced-apart support surface attachment devices100′. In particular, as shown in the end view of FIG. 72, the skirtmember 174″ engages with the upper clamp member 10′ and the lower clampmember 20′ of the clamp assembly 126′ of the support surface attachmentdevice 100′. As shown in this figure, the skirt member 174″ isclampingly engaged by the upper clamp member 10′, and is additionallyengaged by the teeth 34′ of the lower clamp member 20′ (e.g., on thesouth side of the clamp). FIG. 72 also illustrates the photovoltaicmodule frame 372 of the photovoltaic module 374 engaged with the side ofthe clamp assembly 10′, 20′ that is opposite to the side on which theskirt member 174″ is engaged (e.g., the north side).

Now, with reference to FIG. 85, an alternative of a lower couplingmember 150″ will be described. The lower coupling member 150″ of FIG. 85is similar in most respects to the lower coupling member 150′ of FIG. 42explained above. Although, unlike the lower coupling member 150′, thefirst and second ledge portions 156′, 158′ of the lower coupling member150″ are provided with respective drainage troughs 157, 159 formedtherein for draining water from one or more photovoltaic modules thatincorporate a module drainage feature.

Referring again to FIGS. 39 and 72, the engagement between the skirtmember 174″ and the lower clamp member 20′ will be explained in moredetail. As shown in the end view of FIG. 39, a backside of the skirtmember 174″ comprises a plurality of downwardly-directed protrusions orteeth 176′ and one or more upwardly-directed protrusions or teeth 180that are spaced apart from one another by elongate grooves or gaps 178′,184. More particularly, the upper two (2) protrusions or teeth 176′ arespaced apart from one another by the narrow width elongate groove 178′,while the pair of upper protrusions or teeth 176′ are spaced apart fromupwardly-directed protrusion or tooth 180 by a wide elongate groove orgap 184. With reference to the end view of FIG. 72, it can be seen thatat least some of the protrusions or teeth 176′, 180 of the skirt member174″ matingly engage with at least some of the protrusions or teeth 34′on the lower clamp member 20′. This engagement between the protrusionsor teeth 34′, 176′, 180 enables the skirt member 174″ to be securelysupported on the clamp assembly 126′. The protrusions or teeth 164′ onthe lower coupling member 150′ engage with the protrusions or teeth176′, 180 of the skirt member 174′″ in a manner that is generally thesame as that of the protrusions or teeth 34′ on the lower clamp member20′. Advantageously, the protrusions or teeth 176′, 180, 34′ on theskirt member 174″ and the lower clamp member 20′, respectively, allowsthe skirt member 174″ to be mounted at various heights relative to thelower clamp member 20′ so that the skirt member 174′ is capable ofmatching the height of many different PV modules. This is importantbecause then the skirt member 174″ sets the gap size of the clampassembly 126′ and the coupling assembly 130′ on the south row of the PVarray to accept the first row of PV modules.

Another embodiment of the skirt member 174′ is illustrated in FIG. 38.The skirt member 174′ of FIG. 38 is similar in many respects to theskirt member 174″ of FIG. 39 that was described above. However, unlikethe skirt member 174″, the skirt member 174′ of FIG. 38 additionallycomprises a V-shaped protrusions or tooth 182 disposed on the backsideof the skirt member 174′. As shown in this figure, the V-shapedprotrusions or tooth 182 is disposed between the bottommostdownwardly-directed protrusion or tooth 176′ and the upwardly-directedprotrusion or tooth 180. The skirt member 174′ of FIG. 38 is designed tobe used with a PV array comprising PV modules with specific heights,while the skirt member 174″ of FIG. 39 is designed to be used with a PVarray comprised of PV modules of different heights. Advantageously, theupwardly-directed protrusions or teeth 34′ on the lower clamp member20′, and the downwardly-directed protrusion or teeth 176′ on the skirtmembers 174′, 174″, allow the skirt members 174′, 174″ to be droppedinto the clamp assemblies 126′ from the side, thereby greatlyfacilitating the installation of the PV array by obviating the need toslide the skirt members 174′, 174″ into the clamp assemblies 126′ fromthe end of the PV array. The skirt members 174′, 174″ are able to beslid into the coupling assemblies 130 without difficulty during theinstallation of the PV array.

Now, with reference to FIGS. 48-71, 79, and 80, various accessories ofthe sloped roof solar panel mounting system will be described.Initially, turning to FIGS. 48-50, the junction box bracket 198, 198′will be explained. In the PV array, the junction box bracket 198, 198′holds a junction box where PV module wires terminate at the end of thearray. The junction box bracket 198, 198′ may be provided withpre-drilled holes or self-drilling/self-tapping screws may be used. Afirst embodiment of the junction box bracket 198 is shown in FIG. 48. InFIG. 48, it can be seen that the junction box bracket 198 comprises abase portion 200 and a flange portion 202, which is disposed atapproximately a ninety (90) degree angle relative to the base portion200. The flange portion 202 of the junction box bracket 198 is attachedto the base member 90′ by a plurality of fasteners 210. To facilitatethe installation of the junction box bracket 198, the fasteners 210 maybe self-drilling and/or self-tapping type fasteners (i.e.,self-drilling/self-tapping bolts or screws).

Like the first embodiment of the junction box bracket 198, the secondembodiment of the junction box bracket 198′ illustrated in FIGS. 49 and50 also comprises a base portion 200′ and a flange portion 202′ that isoriented at a substantially ninety (90) degree angle relative to thebase portion 200′. However, as shown in these two figures, the baseportion 200′ of the junction box bracket 198′ may be predrilled with aplurality of apertures 204 for mounting the junction box thereto. Also,the flange portion 202′ of the junction box bracket 198′ may bepredrilled with a plurality of apertures 206 disposed along the lengththereof for securing the junction box bracket 198′ to the base member90′. In addition, as shown in FIG. 49, the junction box bracket 198′ maybe provided with prepackaged fasteners 208 for mounting the junction boxto the junction box bracket 198′ and/or for mounting the junction boxbracket 198′ to the base member 90′.

A third embodiment of the junction box bracket is illustrated in FIGS.79 and 80. Unlike the junction box brackets 198, 198′ of FIGS. 48-50,the junction box bracket 340 in FIGS. 79 and 80 is in the form of acenter-mounted junction box bracket. That is, the junction box bracket340 is configured to be center-mounted on the base member 90′. In FIGS.79 and 80, it can be seen that the junction box bracket 340 generallycomprises a plate-like base portion 342, a first flange portion 344, anda second flange portion 346 spaced apart from the first flange portion344. The first and second flange portions 344, 346 extend from one sideof the plate-like base portion 342 of the junction box bracket 340, andtogether define a slot for receiving a cross-sectional portion of thebase portion 90′ therein. As shown in these two figures, the plate-likebase portion 342 of the junction box bracket 340 comprises a pluralityof apertures 348 and a plurality of elongate slots 350 disposedtherethrough for attaching a wide variety of different junction boxes tothe junction box bracket 340. Also, the first and second flange portions344, 346 of the junction box bracket 340 may be predrilled with aplurality of apertures 352 disposed therethrough for accommodatingfasteners that secure the junction box bracket 340 to the base member90′. The aperture 352 mounted in the horizontal portion of the secondflange portion 346 in FIGS. 79 and 80 may be used for mounting agrounding lug.

A fourth embodiment of the junction box bracket is illustrated in FIG.84. Unlike the junction box bracket 340 of FIGS. 79 and 80, the junctionbox bracket 340′ in FIG. 84 is in the form of an offset-mounted junctionbox bracket. That is, the first and second flange portions 344′, 346′ ofthe junction box bracket 340′ are offset from a center position of thebracket base portion 342 in a widthwise direction of the bracket baseportion 342 so as to facilitate a connection of one or more wires to thejunction box (or other electrical accessory mounted on the bracket baseportion 342) without the upstanding base member 90′ of the base assembly128′ interfering with a routing of the one or more wires.

Next, with reference to FIGS. 51-56, the power accessory bracket 212will be described. As shown in the perspective view of FIG. 51, thepower accessory bracket 212 is used to mount a power accessory (such asa micro-inverter or optimizer) to the aluminum frame 226 of thephotovoltaic (PV) module. The teeth 214 on the underside of the poweraccessory bracket 212 electrically connect the bracket to the aluminumframe 226 of the PV module (see FIGS. 51 and 52). With combinedreference to FIGS. 51, 52, and 53, it can be seen that themicro-inverter mounting plate 224 is attached to the power accessorybracket 212 by means of a threaded fastener 218 (e.g., a bolt) and acaptive nut 220 that threadingly engages with the fastener 218. As shownin FIG. 54, the captive nut 220 has a threaded aperture 222 thatreceives the shaft of the threaded fastener 218. During the assembly ofthe components, the captive nut 220 is pressed into the central aperture216 of the power accessory bracket 212. In FIG. 56, it can be seen thatthreaded fastener 218, like the threaded fastener member 38 describedabove, is provided with a head portion having a serrated flange 219 forelectrical grounding/bonding purposes.

Turning to FIGS. 57-63, the north row extension assembly 250 of the PVarray mounting system will be explained. Initially, with reference toFIGS. 57 and 58, it can be seen that the illustrative embodiment of thenorth row extension assembly 250 generally includes a north rowextension member 230 and an upper end clamp member 252. As best shown inthe assembled view of FIG. 57, the upper end clamp member 252 and thenorth row extension member 230 are connected to one another by means ofa threaded fastener member 270 and a captive nut 228. Similar to thethreaded fastener member 38 described above, the threaded fastenermember 270 is in the form of a bolt with a head portion having aserrated flange 272 (refer to FIG. 61). As shown in FIG. 59, the captivenut 228 has a threaded aperture 229 that receives the shaft of thethreaded fastener 270. The north row extension assembly 250 attaches toa base member 90′ of the PV array mounting system by means of a pair ofthreaded fastener members 264 that threadingly engage with respectivestrut nuts 72. A pair of threaded fastener members 264 and correspondingstrut nuts 72 are used for securing the north row extension assembly 250to the base member 90′, rather than just a single threaded fastenermember 264 and strut nut 72, in order to provide added stability. Likethe end clamp threaded fastener 270, the threaded fastener member 264 ofthe illustrative embodiment is in the form of a bolt with a head portionhaving a serrated flange 266 (refer to FIG. 62). Also, as shown in FIG.62, the top surface of the head portion of the threaded fastener member264 is provided with a visual indicator line 268 formed therein forindicating the orientation of the strut nut 72 that is threadinglyengaged with the threaded fastener member 264. The north row extensionassembly 250 is used when a clamp located at or near the peak of theroof is desired and it would be difficult or not possible to install aflashing at that location because there are not enough shingle coursesup-roof of the location to allow the flashing to be installed. As aresult, the flashing member 118′ is required to be placed under ashingle course that is two courses down from the peak of the roof. Thenorth row extension assembly 250 operates as a cantilevered mounting armfor securing the north row edge of the PV module array.

Now, with reference primarily to FIG. 63, the structure of the north rowextension member 230 of the north row extension assembly 250 will bedescribed. As shown in FIG. 63, like the glider member 60′ describedabove, it can be seen that the north row extension member 230 comprisesa generally inverted, U-shaped profile with a top wall portion 236 andfirst and second opposed wall portions 238, 240 extending downwardlyfrom the top wall portion 236. The top wall portion 236 comprises aplurality of spaced-apart fastener apertures 234 disposed near a firstlongitudinal end thereof for receiving the strut nut fastener members264 described above, and a single fastener aperture 242 disposed nearthe second, opposite longitudinal end thereof for receiving the endclamp fastener 270. The plurality of spaced-apart fastener strutapertures 234 advantageously permits the locations of the strut nutfastener members 264 to be adjusted. In FIG. 63, it can be seen that theinner surfaces of each of the first and second opposed wall portions238, 240 comprises a pair of elongate protrusions or teeth 244 that arespaced apart from one another by a respective elongate groove 246. Thepair of teeth 244 on each of the inner surfaces of the opposed wallportions 238, 240 are designed to engage with respective teeth 110 onopposed upstanding wall portions 104 a′, 104 b′ of the base member 90′.The north row extension member 230 may be slid into place on the top ofthe base member 90′ by engaging its teeth 244 with the teeth 110 of thebase member 90′. To permit horizontal adjustability, the north rowextension member 230 is capable of being slid along the length of thebase member 90′. And, to permit vertical adjustability, the north rowextension member 230 is capable of being adjustably placed along avertical height of the upstanding wall portions 104 a′, 104 b′ of thebase member 90′ by selectively engaging certain ones of the teeth 244 onthe north row extension member 230 with certain ones of the grooves 112on the base member 90′, and the groove 246 on the north row extensionmember 230 with a certain one of the teeth 110 on the base member 90′.

As best shown in FIG. 63, the outer sides of the first and secondopposed wall portions 238, 240 of the north row extension member 230 areprovided with a plurality of generally parallel, visual indicatorgrooves 232 formed therein (e.g., three (3) visual indicator grooves232). During the installation of the PV modules, the visual indicatorgrooves 232 operate as visual indicating bands for positioning the northrow extension member 230 at its desired height (i.e., the visualindicator grooves 232 enable the desired height of the north rowextension member 230 relative to the base member 90′ to be more easilyobtained by the installer during the PV module installation process).

Next, turning to FIG. 60, the structure of the upper end clamp member252 will be explained. The upper end clamp member 252 secures the northedge of the PV module in the PV array. As shown in this figure, theupper end clamp member 252 generally includes a vertical body portion254 that is attached to a horizontal flange portion 260 at approximatelya 90 degree angle. In this figure, it can be seen that vertical bodyportion 254 of the upper end clamp member 252 has an offset 256 formedtherein. Referring again to FIG. 60, it can be seen that the flangeportion 260 of the upper end clamp member 252 further comprises afastener aperture 258 for receiving the threaded fastener member 270.Also, as shown in FIG. 60, the flange portion 260 includes an elongategroove 262 disposed in the bottom surface thereof. The elongate groove262 of the upper end clamp member 252 is configured to receive aprojection portion 49′ of a respective bonding clip 42″ (see FIG. 58)that provides integrated grounding for the photovoltaic moduleinstallation. The projection portion 49′ of the bonding clip 42″ isreceived within the elongate groove 262 of upper end clamp member 252 ina press-fit or interference-fit type mounting arrangement.

Turning to FIGS. 82 and 83, an alternative embodiment of the north rowextension assembly 250′ of the PV array mounting system will bedescribed. The north row extension assembly 250′ of FIGS. 82 and 83 issimilar in many respect to the north row extension assembly 250explained above. However, unlike the north row extension assembly 250 ofFIG. 57, the north row extension assembly 250′ utilizes a clamp assemblycomprising the upper clamp member 10 and the lower clamp member 20′described above, rather than the upper end clamp member 252. In asimilar manner to that described above for the support surfaceattachment device 100′, the clamp members 10, 20′ are used to secure oneor more photovoltaic modules to the north row extension assembly 250′.Turning again to FIGS. 82 and 83, it can be seen that the north rowextension member 230′ of the north row extension assembly 250′ isslightly different that the north row extension member 230 describedabove. For example, the north row extension member 230′ contains agreater number of spaced-apart fastener apertures 234 than the north rowextension member 230, and the north row extension member 230′ containsan elongated slot 242′ for receiving the clamp fastener 270′, ratherthan a circular aperture 242. Rather than being provided with thecaptive nut 228 at the distal end thereof, the clamp fastener 270′ isprovided with a modified strut nut 227 for securing the clamp assemblyto the north row extension member 230′.

Referring to the exploded view of FIG. 58, the O-ring member 248 of thenorth row extension assembly 250 is used to maintain a predeterminedspacing distance or gap between the flange portion 260 of the upper endclamp member 252 and the top wall portion 236 of the north row extensionmember 230. In other words, the O-ring member 248 is used to hold upperend clamp member 252 open so that a PV module may be more easilyinserted between the flange portion 260 of the upper end clamp member252 and the top wall portion 236 of the north row extension member 230during the installation of the PV module array on the roof.

An embodiment of an upstanding tile base member 274 is illustrated inFIG. 64. The upstanding tile base member 274 of FIG. 64 is configured tobe attached to a PV tile mounting solution (such as a tile replacementbracket or a tile hook). The tile base member 274 is capable of beingused in any location within the array. Referring to FIG. 64, it can beseen that the upstanding tile base member 274 generally comprises a baseportion 276 and a pair of opposed first and second upstanding wallportions 278, 280 extending upwardly from the base portion 276 of theupstanding tile base member 274. In FIG. 64, it can be seen that theouter surfaces of each of the first and second opposed upstanding wallportions 278, 280 comprises a plurality of elongate protrusions or teeth286 that are each spaced apart from one another by respective elongategrooves 288. The set of teeth 286 on each of the outer surfaces of theopposed wall portions are designed to engage with the respective teeth68′ on the opposed wall portions 66 a′, 66 b′ of the glider member 60′.Also, as shown in FIG. 64, the opposed wall portions 278, 280 of theupstanding tile base member 274 cooperate to define an upper elongateslot 282 that accommodates the shaft of the threaded fastener member 38passing therethrough. Also, each of the opposed wall portions 278, 280comprises a downturned lip portion 284 that is received within arespective one of the elongate grooves 76 disposed in the top surface ofthe strut nut 72.

An alternative embodiment of the upstanding tile base member is shown inFIG. 87. The upstanding tile base member 274′ of FIG. 87 is similar inmost respects to the upstanding tile base member 274 described above.However, as shown in FIG. 87, the upstanding tile base member 274′ has alonger profile length as compared to the base member 274 of FIG. 64.

Turning to FIGS. 65-67, the south row mounting assembly 290 of the PVarray mounting system will be explained. Initially, with reference toFIGS. 65 and 66, it can be seen that the illustrative embodiment of thesouth row mounting assembly 290 generally includes an elongated glidermember 292 and an upper end clamp member 252. As best shown in theassembled view of FIG. 65 and the exploded view of FIG. 66, the upperend clamp member 252 and the elongated glider member 292 are connectedto one another by means of a threaded fastener member 270 and a captivenut 228. The south row mounting assembly 290 attaches to a base member90′ of the PV array mounting system by means of a threaded fastenermember 264 that threadingly engages with a strut nut 72. The south rowmounting assembly 290 may be used on the south edge of the PV modulearray in lieu of the double clamp assembly 126′ and the skirt member174′, 174″. From an aesthetic standpoint, the south row mountingassembly 290 may be used as an alternative to the skirt member 174′,174″.

Now, with reference primarily to FIG. 67, the structure of the elongatedglider member 292 of the south row mounting assembly 290 will bedescribed. As shown in FIG. 67, like the glider member 60′ describedabove, it can be seen that the elongated glider member 292 comprises agenerally inverted, U-shaped profile with a top wall portion 298 andfirst and second opposed wall portions 300, 302 extending downwardlyfrom the top wall portion 298. The top wall portion 236 comprises afirst fastener aperture 296 disposed near a first longitudinal endthereof for receiving the strut nut fastener member 264 described above,and a second fastener aperture 304 disposed near the second, oppositelongitudinal end thereof for receiving the end clamp fastener 270. InFIG. 67, it can be seen that the inner surfaces of each of the first andsecond opposed wall portions 300, 302 comprises a pair of elongateprotrusions or teeth 306 that are spaced apart from one another by arespective elongate groove 308. The pair of teeth 306 on each of theinner surfaces of the opposed wall portions 300, 302 are designed toengage with respective teeth 110 on opposed upstanding wall portions 104a′, 104 b′ of the base member 90′. The elongated glider member 292 maybe slid into place on the top of the base member 90′ by engaging itsteeth 306 with the teeth 110 of the base member 90′. To permithorizontal adjustability, the elongated glider member 292 is capable ofbeing slid along the length of the base member 90′. And, to permitvertical adjustability, the elongated glider member 292 is capable ofbeing adjustably placed along a vertical height of the upstanding wallportions 104 a′, 104 b′ of the base member 90′ by selectively engagingcertain ones of the teeth 306 on the elongated glider member 292 withcertain ones of the grooves 112 on the base member 90′, and the groove308 on the elongated glider member 292 with a certain one of the teeth110 on the base member 90′.

As best shown in FIG. 67, the outer sides of the first and secondopposed wall portions 300, 302 of the elongated glider member 292 areprovided with a plurality of generally parallel, visual indicatorgrooves 294 formed therein (e.g., three (3) visual indicator grooves294). During the installation of the PV modules, the visual indicatorgrooves 294 operate as visual indicating bands for positioning the southrow mounting assembly 290 at its desired height (i.e., the visualindicator grooves 294 enable the desired height of the south rowmounting assembly 290 relative to the base member 90′ to be more easilyobtained by the installer during the PV module installation process).Because the upper end clamp member 252 of the south row mountingassembly 290 is generally the same as that described above for the northrow extension assembly 250, in the interest of brevity, it will not bedescribed again in conjunction with the south row mounting assembly 290.

Referring to the exploded view of FIG. 66, the O-ring member 248 of thesouth row mounting assembly 290 performs the same functionality asdescribed above for the north row extension assembly 250. That is, theO-ring member 248 is used to hold upper end clamp member 252 open sothat a PV module may be more easily inserted between the flange portion260 of the upper end clamp member 252 and the top wall portion 298 ofthe south row mounting assembly 290 during the installation of the PVmodule array on the roof.

Next, referring to FIGS. 68-71, the south row, single-sided couplingassembly 310 of the PV array mounting system will be explained. Similarto the coupling assemblies 130, 130′ described above, south row couplingassembly 310 generally includes an upper coupling member 312 secured toa lower coupling member 324. As best shown in the assembled view of FIG.68, the upper coupling member 312 and the lower coupling member 324 areconnected to one another by means of one or more threaded fastenermembers 168 (e.g., two (2) threaded fastener members 168) and one ormore respective captive nuts 170 (e.g., two (2) captive nuts 170, onefor each threaded fastener member 168). In the illustrated embodiment,each threaded fastener member 168 is in the form of a bolt with a headportion having a serrated flange (e.g., refer to FIG. 68). The south rowcoupling assembly 310 may be used on the south edge of the PV modulearray when the south row mounting assembly 290 is used in lieu ofproviding the skirt member 174′, 174″ on the south row. As shown inFIGS. 70 and 71, unlike the coupling assembly 130′ described above, theupper and lower coupling members 312, 324 of the skirtless couplingassembly 310 do not comprise any mating teeth or protrusions disposedthereon.

Turning to FIG. 70, the structure of the upper coupling member 312 ofthe south row coupling assembly 310 will be described. As shown in thisfigure, the upper coupling member 312 generally includes a vertical bodyportion 314 that is attached to a horizontal flange portion 316 atapproximately a 90 degree angle. Referring again to FIG. 70, it can beseen that the flange portion 316 of the upper coupling member 312further comprises a plurality of fastener apertures 318, 320 forreceiving respective threaded fastener members 168. In the illustrativeembodiment of FIG. 70, it can be seen that the first fastener aperture318 has a generally oval shape, while the second fastener aperture 320has a generally circular shape. Also, as shown in FIG. 70, the flangeportion 316 includes an elongate groove 322 disposed in the bottomsurface thereof. The elongate groove 316 is configured to receive one ormore projection portions 49, 49′ of the bonding clip 42′, 42″ thatprovides integrated grounding for the photovoltaic module installation(see e.g., FIG. 69). The projection portion 49, 49′ of the bonding clip42′, 42″ is received within the elongate groove 316 in a press-fit orinterference-fit type mounting arrangement.

Next, turning to FIG. 72, the structure of the lower coupling member 324of the south row coupling assembly 310 will be explained. With referenceto this figure, it can be seen that the lower coupling member 324generally includes an upstanding portion 326 with a ledge portion 336extending outwardly from one side of the upstanding portion 326. In FIG.71, it can be seen that the upstanding portion 326 of the lower couplingmember 324 comprises spaced-apart threaded fastener apertures 334disposed therethrough. Each of these apertures 334 receives a respectiveshaft of a respective threaded fastener member 168. The upstandingportion 326 of the lower coupling member 324 further comprises a topwall portion 328 and first and second opposed wall portions 330, 332extending downwardly from the top wall portion 328. The ledge portion336 of the lower coupling member 324 is configured to accommodate aphotovoltaic module frame member resting thereon (i.e., a frame memberof a south row PV module).

Referring to the exploded view of FIG. 69, the O-ring member 248 of thesouth row coupling assembly 310 performs generally the samefunctionality as described above for the north row extension assembly250 and the south row mounting assembly 290. That is, the O-ring member248 is used to hold upper coupling member 312 open so that a PV modulemay be more easily inserted between the flange portion 316 of the uppercoupling member 312 and the ledge portion 336 of the lower couplingmember 324 during the installation of the PV module array on the roof.

Now, turning to FIG. 86, an illustrative embodiment of a conduitmounting member 360 will be described. The conduit mounting member 360is configured to couple electrical conduit of a photovoltaic system toan upstanding base member 90′ of a base assembly 128′. The conduitmounting member 360 is configured to mount a conduit strap or otherconduit holding device such that conduit of a photovoltaic system can bemounted to the conduit mounting member 360. As shown in FIG. 86, theconduit mounting member 360 includes a generally vertical securementportion 362 comprising a plurality of spaced-apart mounting apertures364 for attaching the conduit mounting member 360 to the upstanding basemember 90′ (e.g., by using one or more tek screws). The conduit mountingmember 360 further comprises a generally horizontal conduit mountingportion 366 connected to the generally vertical securement portion 362.The conduit mounting portion 366 comprises a plurality of spaced-apartsecurement apertures 368 for attaching the electrical conduit to theconduit mounting member 360 (e.g., by using a conduit strap). As shownin the illustrative embodiment of FIG. 86, the conduit mounting member360 resembles the shape of angle iron flange, wherein the generallyvertical securement portion 362 is disposed generally transverselyrelative to the horizontal conduit mounting portion 366.

Turning to FIG. 88, an illustrative photovoltaic system 400 utilizingthe constituent mounting system components described herein is shown.FIG. 88 illustrates a roof-mounted photovoltaic (PV) system or arrayaccording to an embodiment of the present invention. The illustratedphotovoltaic system or array includes an array of solar panels or PVmodules 374 mounted to a pitched or sloped support surface in the formof a building rooftop 370 by a mounting system. For clarity ofillustration of the mounting components, the photovoltaic module frames372 are primarily shown in FIG. 88 rather than the full modules 374,with one exemplary full PV module 374 illustrated in the south row. InFIG. 88, there are three (3) rows of PV modules 374 illustrated forexemplary purposes, each of the first two rows having three (3) PVmodules 374 disposed therein, and the third row (i.e., the north row)having only one PV modules 374 disposed therein. The illustratedmounting system includes a plurality of support surface attachmentdevices 100′ that secure the photovoltaic module frames 372 to thebuilding rooftop 370. The PV array illustrated in FIG. 88 has each ofthe rectangular-shaped PV modules 374 oriented in a landscapeorientation, that is, with the longest axis of the PV modules extendingin a lateral or side-to-side direction which is typically the east-westdirection. It is noted, however, that the PV modules can alternativelybe oriented by the support surface attachment devices 100′ in a portraitorientation, that is, with the longest axis of the PV modules extendingin a forward-rearward direction which is typically the south-northdirection. With reference again to FIG. 88, it can be seen that theillustrated mounting system also includes a plurality of couplingdevices 130′ that rigidly fasten a plurality of PV modules 374 to oneanother. As shown in FIG. 88, the coupling devices 130′ connect thecorners of adjacent PV modules 374 together. Also, an exemplary sectionof a skirt member 174″ is depicted on the south edge of the PV array inFIG. 88. On the north edge of the PV array in FIG. 88, north rowextension assemblies 250′ are shown supporting the north side of aphotovoltaic module frame 372 in a cantilevered manner. As explainedabove, the north row extension assemblies 250′ advantageously allows anadditional north row of PV modules to be installed in the array at ornear the ridge/peak of the 370 where support surface attachment devices100′ are unable to be accommodated on the north sides of the PV modules(e.g., because shingle courses are unable to be loosened in roof ridgearea). Referring again to FIG. 88, it can be seen that a junction boxbracket 340′ is mounted to the upstanding base member 90′ of the supportsurface attachment devices 100′ of the leftmost PV module in the secondrow of the PV module array to support a junction box or other electricalaccessory of the photovoltaic system.

Another illustrative embodiment of a clamp assembly is seen generally at126″ in FIGS. 89-93. Referring to these figures, it can be seen that, insome respects, the illustrative embodiment of FIGS. 89-93 is similar tothat of the preceding embodiments of the clamp assembly. Moreover, someelements are common to all of these embodiments. For the sake ofbrevity, the elements that the embodiment of the clamp assembly of FIGS.89-93 has in common with the preceding embodiments will not be discussedin detail because these components have already been described above.

Initially, with reference to FIGS. 89 and 92, it can be seen that theillustrative clamp assembly 126″ generally includes an upper clampmember 402, a lower clamp member 414, and a glider member 60′ to engagewith the base assembly. Also, as shown in FIGS. 89 and 92, the upperclamp member 402, lower clamp member 414, and the glider member 60′ areconnected to one another by means of a threaded fastener member 38 and astrut nut 72. The threaded fastener member 38 and strut nut 72 are thesame as those described above in conjunction with the precedingembodiments. In addition, as shown in the exploded view of FIG. 89, likethe embodiment of FIG. 44 described above, an O-ring 196 is provided onthe shaft of the threaded fastener member 38 to stabilize the clampassembly on the glider member 60′ prior to installation.

Now, with reference to FIGS. 107A-110, the structure of the upper clampmember 402 of the clamp assembly in the embodiment of FIGS. 89-93 willbe described. Referring initially to the perspective view of FIG. 107A,it can be seen that the upper clamp member 402 generally includes a pairof spaced-apart downwardly extending portions 408, 410 that are attachedto a top clamp portion 404. In the illustrative embodiment, each of thedownwardly extending portions 408, 410 has a generally U-shapedcross-section, while the top clamp portion 404 comprises a central plateportion with a peripheral lip disposed therearound. Referring again toFIGS. 107A and 110, it can be seen that the top clamp portion 404 of theupper clamp member 402 further comprises a fastener aperture 406 forreceiving the threaded fastener member 38. Also, as best shown in FIGS.107A and 108, the top clamp portion 404 of the upper clamp member 402forms a pair of oppositely disposed flange portions for engaging the topsurfaces of one or more photovoltaic modules. The first oppositelydisposed flange portion of the top clamp portion 404 is shorter than thesecond oppositely disposed flange portion. Like the precedingembodiments described above, the upper clamp member 402 enables the oneor more photovoltaic modules to be pivotably installed into the firstside of the clamp assembly (e.g., into the side of clamp assembly withthe short flange portion). In addition, as best illustrated in FIGS.107A and 107B, the shorter flange portion of the top clamp portion 404of the upper clamp member 402 comprises integrated grounding means,which are configured to provide integrated grounding between adjacentphotovoltaic modules. More particularly, in the illustrative embodiment,with reference to FIGS. 107A and 107B, the integrated grounding means ofthe upper clamp member 402 comprises two spaced-apart groundingprotrusions or teeth 412. The downwardly inclined, pointed groundingprotrusions or teeth 412 are designed to pierce the anodized layer ofthe photovoltaic module to provide integrated grounding between thephotovoltaic modules. To facilitate integrated grounding between thephotovoltaic modules, all of the components of the support surfaceattachment device and the coupling device may be formed from metal.

Next, turning to FIGS. 103-106, the structure of the lower clamp member414 of the clamp assembly embodiment of FIGS. 89-93 will be explained.Referring initially to the perspective view of FIG. 103, it can be seenthat the lower clamp member 414 generally includes a pair ofspaced-apart upwardly extending portions 416, 418 that are attached to abase portion 424. In FIG. 103, it can be seen that the base portion 424of the lower clamp member 414 comprises a fastener aperture 430 disposedtherethrough. The fastener aperture 430 receives the shaft of thethreaded fastener member 38. Also, as best shown in FIG. 103, the baseportion has a generally U-shaped cross-section with oppositely disposedfirst and second upturned edges 426, 428. As best shown in the side viewof FIG. 104A, the base portion 424 of the lower clamp member 414 has twoledge portions, each of which is disposed on a respective opposite sideof the upwardly extending portions 416, 418. Each of the ledge portionsof the base portion 424 of the lower clamp member 424 is configured toaccommodate a photovoltaic module frame member resting thereon. Similarto that described above for the preceding embodiments of the lower clampmember, the upturned edges 426, 428 that form the opposed lateral sidesof the clamp ledge portions each are tapered slightly upward at an acuteangle (see FIGS. 103 and 104A, so as to be capable of performing thesame functionality explained above for the lower clamp members 20, 20′(i.e., the ability for an installer to pivot the north row of PV modulesinto place). As shown in FIGS. 103 and 104A, in the illustrativeembodiment, the spaced-apart upwardly extending portions 416, 418 are inthe form of first and second vertical walls. In the illustrativeembodiment, each of the upwardly extending portions 416, 418 of thelower clamp member 414 comprises a pair of oppositely disposed,outwardly extending protrusions 420. The outwardly extending protrusions420 are configured to facilitate the holding open of the panel receivinggap of the clamp assembly during the installation of the photovoltaicmodules. In the illustrative embodiment, the outwardly extendingprotrusions 420 are further configured to be deformed and/or severedfrom the remainder of the upwardly extending portion 416, 418 of thelower clamp member 414 when the fastener member 38 of the clamp assemblyis tightened (i.e., the outwardly extending protrusions 420 are in theform of breakaway protrusions). As best shown in FIGS. 103, 104A, and104B, a skirt receiving notch 422 is provided next to each of theupwardly extending portions 416, 418 of the lower clamp member 414. Theskirt receiving notches 422 are configured to receive a downturned edgeportion 600 of a skirt member 596 (see FIGS. 160 and 161). As shown inFIG. 161, the skirt member 596 comprises a body portion 598 with thedownturned edge portion 600 disposed on the north side of the bodyportion 598.

In the illustrative embodiment of the clamp assembly described above,the spaced-apart downwardly extending portions 408, 410 of the upperclamp member 402 are configured to engage with the upwardly extendingportions 416, 418 of the lower clamp member 414 so as to hold open thepanel receiving gap of the clamp assembly for facilitating an insertionof the one or more photovoltaic modules after the fastener member 38 ofthe clamp assembly has been partially tightened (i.e., to allow for theuniversal setting of the clamp).

Yet another illustrative embodiment of a clamp assembly is seengenerally at 126′″ in FIGS. 94-98. Referring to these figures, it can beseen that, in some respects, the illustrative embodiment of FIGS. 94-98is similar to that of the preceding embodiments of the clamp assembly.Moreover, some elements are common to all of these embodiments. For thesake of brevity, the elements that the embodiment of the clamp assemblyof FIGS. 94-98 has in common with the preceding embodiments will not bediscussed in detail because these components have already been describedabove.

Initially, with reference to FIGS. 94 and 98, it can be seen that theillustrative clamp assembly 126′″ generally includes an upper clampmember 432, a lower clamp member 494, and a glider member 60′ to engagewith the base assembly. Also, as shown in FIGS. 94 and 98, the upperclamp member 432, lower clamp member 494, and the glider member 60′ areconnected to one another by means of a threaded fastener member 38 and astrut nut 72. The threaded fastener member 38 and strut nut 72 are thesame as those described above in conjunction with the precedingembodiments.

Now, with reference to FIGS. 123A-126, the structure of the upper clampmember 432 of the clamp assembly embodiment of FIGS. 94-98 will bedescribed. Referring initially to the perspective view of FIG. 123A, itcan be seen that the upper clamp member 432 generally includes a pair ofspaced-apart downwardly extending portions 438, 440 that are attached toa top clamp portion 434. In the illustrative embodiment, each of thedownwardly extending portions 438, 440 has a generally U-shapedcross-section, while the top clamp portion 434 comprises a middle plateportion with oppositely disposed flanged portions. Referring again toFIGS. 123A and 126, it can be seen that the top clamp portion 434 of theupper clamp member 432 further comprises a fastener aperture 436 forreceiving the threaded fastener member 38. Also, as best shown in FIGS.123A and 125, the top clamp portion 434 of the upper clamp member 432forms a pair of oppositely disposed flange portions for engaging the topsurfaces of one or more photovoltaic modules. The first oppositelydisposed flange portion of the top clamp portion 434 is shorter than thesecond oppositely disposed flange portion. Like the precedingembodiments described above, the upper clamp member 432 enables the oneor more photovoltaic modules to be pivotably installed into the firstside of the clamp assembly (e.g., into the side of clamp assembly withthe short flange portion). In addition, as best illustrated in FIGS.123A and 123B, the shorter flange portion of the top clamp portion 434of the upper clamp member 432 comprises integrated grounding means,which are configured to provide integrated grounding between adjacentphotovoltaic modules. More particularly, in the illustrative embodiment,with reference to FIGS. 123A and 123B, the integrated grounding means ofthe upper clamp member 432 comprises two spaced-apart groundingprotrusions or teeth 442. The downwardly inclined, pointed groundingprotrusions or teeth 442 are designed to pierce the anodized layer ofthe photovoltaic module to provide integrated grounding between thephotovoltaic modules. To facilitate integrated grounding between thephotovoltaic modules, all of the components of the support surfaceattachment device and the coupling device may be formed from metal.

Referring again to FIGS. 123A and 123B, it can be seen that each of thedownwardly extending portions 438, 440 of the upper clamp member 432 hasa dimple 446 formed in a vertical side surface thereof. The dimples 446of the upper clamp member 432 are configured to facilitate the holdingopen of the panel receiving gap of the clamp assembly. In theillustrative embodiment, as best shown in FIGS. 123A and 125, the topclamp portion 434 of the upper clamp member 432 further comprises ahemmed portion that forms a skirt receiving groove 444. The skirtreceiving groove 444 is configured to receive a downwardly extendinghemmed upper edge portion 538 of a skirt member 534 (see FIG. 168). Asshown in FIG. 168, once the hemmed upper edge portion 538 of a skirtmember 534 is inserted into the skirt receiving groove 444 of the upperclamp member 432, the skirt member 534 is secured to the clamp assemblyby means of the head of the fastener member 38 (i.e., the head of thefastener member 38 presses down on the top surface of the skirt member534).

Next, turning to FIGS. 99-102, the structure of the lower clamp member494 of the clamp assembly embodiment of FIGS. 94-98 will be explained.Similar to that described above for the lower clamp members 20, 20′, itcan be seen that the lower clamp member 494 generally includes anupstanding middle portion 495 with first and second ledge portions 497,498 extending outwardly from the upstanding middle portion 495 (refer toFIGS. 99 and 100). In FIGS. 99 and 101, it can be seen that theupstanding middle portion 495 of the lower clamp member 494 comprises afastener aperture 496 disposed centrally therethrough. The fasteneraperture 496 receives the shaft of the threaded fastener member 38. Asshown in FIGS. 99 and 100, the upstanding middle portion 495 of thelower clamp member 494 comprises a top wall portion with aperture 496that is connected to first and second opposed vertical wall portions.Each of the first and second ledge portions 497, 498 of the lower clampmember 494 is configured to accommodate a photovoltaic module framemember resting thereon. As described above for the preceding embodimentsof the lower clamp member 20, 20′, the second opposed ledge 498 of thelower clamp member 494 is bent slightly upward, or is tapered slightlyupward at an acute angle, so as to be capable of performing the samefunctionality explained above for the lower clamp members 20, 20′ (i.e.,the ability for an installer to pivot the north row of PV modules intoplace).

In the illustrative embodiment of the clamp assembly described above,the spaced-apart downwardly extending portions 438, 440 of the upperclamp member 432 are configured to engage with opposite sides of theupstanding middle portion 495 of the lower clamp member 494 so as tohold open the panel receiving gap of the clamp assembly for facilitatingan insertion of the one or more photovoltaic modules after the fastenermember 38 of the clamp assembly has been partially tightened (i.e., toallow for the universal setting of the clamp).

Advantageously, the panel receiving gap defined by the upper and lowerclamp members 402, 414 and 432, 494 of the clamp assemblies describedabove is continuously adjustable by a user within the range betweenapproximately 32 millimeters and approximately 50 millimeters so as toaccommodate any photovoltaic module thickness within that range. Thatis, the clamp assemblies are capable of accommodating any photovoltaicmodule thickness between 32 millimeters and 50 millimeters, such as butnot limited to, photovoltaic module thicknesses of 32 millimeters, 35millimeters, 40 millimeters, 45 millimeters, and 46 millimeters. In theillustrative embodiment, the panel receiving gap defined by the upperand lower clamp members 402, 414 and 432, 494 of the clamp assemblies isnot limited to incremental adjustment, rather it is continuouslyadjustable between 32 millimeters and 50 millimeters. In addition, theclamp assemblies with the upper and lower clamp members 402, 414 and432, 494 are capable of being rotated 360 degrees relative to the baseassembly of the support surface attachment device so as to accommodatevarious photovoltaic module mounting arrangements (e.g., the clampmembers 402, 414 and 432, 494 could be rotated 90 degrees to accommodatea side mounting arrangement on the photovoltaic module). Further, theclamp assemblies with the upper and lower clamp members 402, 414 and432, 494 are capable of being interchangeably used with or without askirt member of a photovoltaic array (i.e., the same clamps can be usedfor both the middle rows of the array and the north and south rows ofthe array). The south row of the array with the skirt member does notrequire a different type of clamp for the skirt member. Also,advantageously, the clamp assemblies with the upper and lower clampmembers 402, 414 and 432, 494 allow for the use of a universal skirt(i.e., it is unnecessary to use different skirts for differentphotovoltaic module heights).

Additional illustrative embodiments of the upper clamp member of theclamp assembly are depicted in FIGS. 111A-114, 115A-118, and 119A-122.These additional upper clamp members may also be used in conjunctionwith the support surface attachment device described herein. Initially,referring to the upper clamp member 448 illustrated in FIGS. 111A-114,it can be seen that the upper clamp member 448 generally includes a topclamp portion 450 with first and second hemmed skirt channel portions454, 456 formed therein. Referring again to FIGS. 111A and 112, it canbe seen that the top clamp portion 450 of the upper clamp member 448further comprises a fastener aperture 452 for receiving the threadedfastener member 38. In FIG. 113, it can be seen that each skirt channelportion 454, 456 forms a respective skirt receiving groove 460, 462.Each of the skirt receiving grooves 460, 462 is configured to receive adownwardly extending hemmed upper edge portion of a skirt member. Thatis, the upper clamp member 448 may be rotated 180 degrees, and still becapable of receiving a skirt member. As described above for the upperclamp member 432, once the hemmed upper edge portion of a skirt member534 is inserted into one of the skirt receiving grooves 460, 462 of theupper clamp member 448, the skirt member is secured to the clampassembly by means of the head of the fastener member 38 (i.e., the headof the fastener member 38 presses down on the top surface of the skirtmember). Also, like the top clamp portion 434 of the upper clamp member432 described above, top clamp portion 450 of the upper clamp member 448forms a pair of oppositely disposed flange portions for engaging the topsurfaces of one or more photovoltaic modules. In addition, like the topclamp portion 434 of the upper clamp member 432, one of the flangeportions of the top clamp portion 450 of the upper clamp member 448comprises integrated grounding means, which are configured to provideintegrated grounding between adjacent photovoltaic modules. Moreparticularly, in the illustrative embodiment, with reference to FIGS.111A and 111B, the integrated grounding means of the upper clamp member448 comprises two spaced-apart grounding protrusions or teeth 458. Thedownwardly inclined, pointed grounding protrusions or teeth 458 aredesigned to pierce the anodized layer of the photovoltaic module toprovide integrated grounding between the photovoltaic modules.

Next, with reference to FIGS. 115A-118, it can be seen that the upperclamp member 464 is similar in many respects to the upper clamp member432 described above. Referring initially to the perspective view of FIG.115A, it can be seen that, like the upper clamp member 432, the upperclamp member 464 generally includes a pair of spaced-apart downwardlyextending portions 470, 472 that are attached to a top clamp portion466. In the illustrative embodiment, each of the downwardly extendingportions 470, 472 has a generally U-shaped cross-section, while the topclamp portion 466 comprises a middle plate portion with oppositelydisposed flanged portions. Referring again to FIGS. 115A and 118, it canbe seen that the top clamp portion 466 of the upper clamp member 464further comprises a fastener aperture 468 for receiving the threadedfastener member 38. Also, as best shown in FIGS. 115A and 117, the topclamp portion 466 of the upper clamp member 464 forms a pair ofoppositely disposed flange portions for engaging the top surfaces of oneor more photovoltaic modules. The first oppositely disposed flangeportions of the top clamp portion 466 are shorter than the secondoppositely disposed flange portion. Like the preceding embodimentsdescribed above, the upper clamp member 464 enables the one or morephotovoltaic modules to be pivotably installed into the first side ofthe clamp assembly (e.g., into the side of clamp assembly with the shortflange portion). In addition, as best illustrated in FIGS. 115A and115B, the shorter flange portions of the top clamp portion 466 of theupper clamp member 464 comprises integrated grounding means, which areconfigured to provide integrated grounding between adjacent photovoltaicmodules. More particularly, in the illustrative embodiment, withreference to FIGS. 115A and 115B, the integrated grounding means of theupper clamp member 464 comprises two spaced-apart grounding protrusionsor teeth 474. The downwardly inclined, pointed grounding protrusions orteeth 474 are designed to pierce the anodized layer of the photovoltaicmodule to provide integrated grounding between the photovoltaic modules.Similar to the top clamp portion 434 of the upper clamp member 432, thetop clamp portion 466 of the upper clamp member 464 comprises a skirtreceiving slot 476 that is configured to receive a downwardly extendinghemmed upper edge portion of a skirt member.

Now, referring to FIGS. 119A-122, it can be seen that the upper clampmember 478 has similar features to the upper clamp members 432, 448described above. Referring initially to the perspective view of FIG.119A, it can be seen that, like the upper clamp member 432, the upperclamp member 478 generally includes a pair of spaced-apart downwardlyextending portions 484, 486 that are attached to a top clamp portion480. In the illustrative embodiment, each of the downwardly extendingportions 484, 486 has a generally U-shaped cross-section, while the topclamp portion 480 comprises a middle portion with oppositely disposedflanged portions. Referring again to FIGS. 119A and 120, it can be seenthat the top clamp portion 480 of the upper clamp member 478 furthercomprises a fastener aperture 482 for receiving the threaded fastenermember 38. Also, as best shown in FIGS. 119A and 121, the top clampportion 480 of the upper clamp member 478 forms a pair of oppositelydisposed flange portions for engaging the top surfaces of one or morephotovoltaic modules. Like the preceding embodiments described above,the upper clamp member 478 enables the one or more photovoltaic modulesto be pivotably installed into the first side of the clamp assembly.Also, similar to the upper clamp member 448, it can be seen that the topclamp portion 480 further comprises first and second hemmed skirtchannel portions formed therein (see FIGS. 119A and 121). Referringagain to FIGS. 119A and 121, it can be seen that each skirt channelportion forms a respective skirt receiving groove 490, 492. Each of theskirt receiving grooves 490, 492 is configured to receive a downwardlyextending hemmed upper edge portion of a skirt member. That is, like theupper clamp member 448 described above, the upper clamp member 478 maybe rotated 180 degrees, and still be capable of receiving a skirtmember. As described above for the upper clamp members 432, 448, oncethe hemmed upper edge portion of a skirt member is inserted into one ofthe skirt receiving grooves 490, 492 of the upper clamp member 478, theskirt member is secured to the clamp assembly by means of the head ofthe fastener member 38 (i.e., the head of the fastener member 38 pressesdown on the top surface of the skirt member). Also, like the top clampportion 450 of the upper clamp member 448 described above, top clampportion 480 of the upper clamp member 478 forms a pair of oppositelydisposed flange portions for engaging the top surfaces of one or morephotovoltaic modules. In addition, like the top clamp portion 450 of theupper clamp member 448, one of the flange portions of the top clampportion 480 of the upper clamp member 478 comprises integrated groundingmeans, which are configured to provide integrated grounding betweenadjacent photovoltaic modules. More particularly, in the illustrativeembodiment, with reference to FIGS. 119A and 119B, the integratedgrounding means of the upper clamp member 478 comprises two spaced-apartgrounding protrusions or teeth 488. The downwardly inclined, pointedgrounding protrusions or teeth 488 are designed to pierce the anodizedlayer of the photovoltaic module to provide integrated grounding betweenthe photovoltaic modules.

Turning to FIGS. 127-131, it can be seen that, like the couplingassemblies 130, 130′ described above, the illustrative embodiment of thecoupling assembly 500 in FIGS. 127-131 generally includes an uppercoupling member 518 secured to a lower coupling member 502. As bestshown in the assembled view of FIG. 130, the upper coupling member 518and the lower coupling member 502 are connected to one another by meansof one or more threaded fastener members 168 (e.g., two (2) threadedfastener members 168). In the illustrated embodiment, each threadedfastener member 168 is in the form of a bolt with a head portion havinga serrated flange (e.g., refer to FIG. 129).

Now, with reference to FIGS. 136-139B, the structure of the uppercoupling member 518 will be described. Initially, as best shown in theperspective view of FIG. 139A, the upper coupling member 518 generallyincludes a top coupling portion 520 with first and second hemmed skirtchannel portions 524, 526 formed therein. Referring to FIGS. 136 and139A, it can be seen that the top coupling portion 520 of the uppercoupling member 518 further comprises a plurality of fastener apertures522 for receiving respective threaded fastener members 168 (e.g., twospaced-apart fastener apertures 522). In FIG. 137, it can be seen thateach skirt channel portion 524, 526 forms a respective skirt receivinggroove 530, 532. Each of the skirt receiving grooves 530, 532 isconfigured to receive a downwardly extending hemmed upper edge portionof a skirt member. That is, the upper coupling member 518 may be rotated180 degrees, and still be capable of receiving a skirt member. Similarto that described above for the upper clamp members, once the hemmedupper edge portion 538 of a skirt member 534 is inserted into one of theskirt receiving grooves 530, 532 of the upper coupling member 518, theskirt member 534 is secured to the coupling assembly 500 by means of theheads of the fastener members 168 (i.e., the head of the fastener member168 presses down on the top surface of the skirt member 534—see FIG.170). Also, like the top clamp portions of the upper clamp membersdescribed above, top coupling portion 520 of the upper coupling member518 forms a pair of oppositely disposed flange portions for engaging thetop surfaces of one or more photovoltaic modules. In addition, like thetop clamp portions of the upper clamp members, one of the flangeportions of the top coupling portion 520 of the upper coupling member518 comprises integrated grounding means, which are configured toprovide integrated grounding between adjacent photovoltaic modules. Moreparticularly, in the illustrative embodiment, with reference to FIGS.139A and 139B, the integrated grounding means of the upper couplingmember 518 comprises a plurality of grounding protrusions or teeth 528(e.g., two pairs of spaced-apart grounding teeth 528). The downwardlyinclined, pointed grounding protrusions or teeth 528 are designed topierce the anodized layer of the photovoltaic module to provideintegrated grounding between the photovoltaic modules.

Next, turning to FIGS. 132-135, the structure of the lower couplingmember 502 will be explained. Similar to that described above for thelower clamp member 494, it can be seen that the lower coupling member502 generally includes an upstanding middle portion 504 with first andsecond ledge portions 512, 514 extending outwardly from the upstandingmiddle portion 504 (refer to FIGS. 132 and 135). In FIGS. 132 and 133,it can be seen that the upstanding middle portion 504 of the lowercoupling member 502 comprises a plurality of threaded fastener apertures506 disposed centrally therein (e.g., two spaced-apart fastenerapertures 506). Each threaded fastener aperture 506 threadingly engagesa respective shaft of a respective threaded fastener member 168. Becauseeach of the apertures 506 is internally threaded, the coupling assembly500 does not require any nuts for the securement of the threadedfastener members 168 (i.e., the threaded fastener apertures 506 operateas built-in nuts). Each threaded fastener aperture 506 may comprise aplurality of extruded threads formed therein for threadingly engaging aplurality of external threads of the threaded fastener member 168 (i.e.,bolt 168). To further stabilize the fastener members 168, fastenerholding protrusions 508 are formed in the sides of the upstanding middleportion 504 (see FIGS. 132, 134, and 135). For example, fastener holdingprotrusions 508 may be in the form of inwardly punched tabs that holdthe fastener members 168 in a vertical position. As shown in FIGS. 132and 135, the upstanding middle portion 504 of the lower coupling member502 comprises a top wall portion with the threaded apertures 506 that isconnected to first and second opposed vertical wall portions. Each ofthe first and second ledge portions 512, 514 of the lower couplingmember 502 is configured to accommodate a photovoltaic module framemember resting thereon. As described above for the preceding embodimentsof the lower coupling members 150, 150′, 150″, the second opposed ledge514 of the lower coupling member 502 is bent slightly upward, or istapered slightly upward at an acute angle, so as to be capable ofperforming the same functionality explained above for the lower couplingmembers 150, 150′, 150″ (i.e., the ability for an installer to pivot thenorth row of PV modules into place).

Referring again to FIGS. 132 and 133, it can seen that, in theillustrative embodiment, the lower coupling member 502 further comprisesa pair of drainage slots 510 formed therethrough for draining water fromthe one or more photovoltaic modules engaged with the coupling assembly500. In addition, in the illustrative embodiment, the lower couplingmember 502 additionally comprises a plurality of diagonally-orientedwater drainage channels 516 formed therein for draining water from oneor more drainage weep holes of the one or more photovoltaic modulesengaged with the coupling assembly 500. Advantageously, the drainageslots 510 and water drainage channels 516 allow the draining of waterfrom one or more photovoltaic modules that incorporate a module drainagefeature.

Advantageously, similar to that described above for the clamp assemblieswith upper and lower clamp members 402, 414 and 432, 494, the panelreceiving gap defined by the upper and lower coupling members 502, 518of the coupling assembly 500 is continuously adjustable by a user withinthe range between approximately 32 millimeters and approximately 50millimeters so as to accommodate any photovoltaic module thicknesswithin that range. That is, the coupling assembly 500 is capable ofaccommodating any photovoltaic module thickness between 32 millimetersand 50 millimeters, such as but not limited to, photovoltaic modulethicknesses of 32 millimeters, 35 millimeters, 40 millimeters, 45millimeters, and 46 millimeters. In the illustrative embodiment, thepanel receiving gap defined by the upper and lower coupling members 502,518 of the coupling assembly 500 is not limited to incrementaladjustment, rather it is continuously adjustable between 32 millimetersand 50 millimeters. In addition, the pair of ledges 512, 514 of thelower coupling member 502 and the pair of flange portions of the uppercoupling member 518 allow the coupling assembly 500 to be rotated 180degrees relative to the one or more photovoltaic modules so that thecoupling assembly 500 is capable of being interchangeably used on northand south rows of a photovoltaic array. Further, the coupling assembly500 with the upper and lower coupling members 502, 518 is capable ofbeing interchangeably used with or without a skirt member of aphotovoltaic array (i.e., the same coupling devices can be used for boththe middle rows of the array and the north and south rows of the array).The south row of the array with the skirt member does not require adifferent type of coupling device for the skirt member. Also,advantageously, the coupling assembly 500 allows for the use of auniversal skirt (i.e., it is unnecessary to use different skirts fordifferent photovoltaic module heights).

With reference to FIGS. 140A-146, another embodiment of a skirt memberof the photovoltaic mounting system will be described. Similar to thatdescribed above for the skirt member 174, the skirt member 534 of FIGS.140A-146 is configured to be located on the southernmost edge of thearray of PV modules. The skirt member 534 is supported by spaced-apartsupport surface attachment devices 100″. In particular, as shown inFIGS. 140A and 140B, the hemmed upper edge portion 538 of the skirtmember 534 engages with the skirt receiving groove 444 of the upperclamp member 432. As described above, the skirt member 534 is secured tothe clamp assembly by means of the head of the fastener member 38 (i.e.,the head of the fastener member 38 presses down on the top surface ofthe skirt member 534—see FIG. 140B). The perspective view of FIG. 140Aillustrates the manner in which the skirt member 534 engages with boththe support surface attachment device 100″ and the coupling device 500.In the detail view of FIG. 141A, it can be seen that the hemmed upperedge portion 538 of the skirt member 534 engages with the skirtreceiving groove 532 of the upper coupling member 518 that is formed bythe skirt channel portion 526.

Now, referring to FIGS. 143-146, the structure of the skirt member 534will described in more detail. As best shown in the end view of FIG.145B, the skirt member 534 comprises a body portion 536 with the hemmedupper edge portion 538 and a curled lower edge portion 540. The curledlower edge portion 540 of the skirt member 534 is configured to receivea pin member therein for facilitating an alignment of multiple skirtsections in a photovoltaic array (i.e., the pin can be used to connectthe lower edge portions of adjacent skirt sections to one another). Thehemmed upper edge portion 538 of the skirt member 534 enhances thestrength of the skirt member 534 and provides a tighter fit in the skirtreceiving grooves 444, 530, 532 of the clamp and coupling assemblies.Advantageously, in the illustrative embodiment, the engagement betweenthe skirt member 534 and the clamp assembly of the support surfaceattachment device 100″, and the engagement between the skirt member 534and the coupling assembly 500, is configured to allow the clamp andcoupling assemblies to accommodate any photovoltaic module thicknesswithin a range between approximately 32 millimeters and approximately 50millimeters. That is, the clamp and coupling assemblies are capable ofaccommodating any photovoltaic module thickness between 32 millimetersand 50 millimeters, such as but not limited to, photovoltaic modulethicknesses of 32 millimeters, 35 millimeters, 40 millimeters, 45millimeters, and 46 millimeters.

Alternative embodiments of coupling members are illustrated in FIGS.147-150. Initially, as shown in FIG. 147, two adjacent photovoltaicmodules 374 are shown coupled to one another by means of an uppercoupling member 542. The upper coupling member 542 in FIG. 147 comprisesa pair of punched down tabs 544 that are used to support thephotovoltaic modules 374. The punched down tabs 544 also prevent thecloseout of the coupling member 542. The lower coupling member 546,which is illustrated in FIGS. 148-150, is configured to be used on thesouthmost row of the photovoltaic array only (i.e., on the row of thephotovoltaic array with the skirt). Referring to FIGS. 148 and 149, itcan be seen that the lower coupling member 546 comprises a lowerplate-like body portion 548 and a curled upper body portion 550 forengaging one or more skirt members. Also, as shown in FIG. 148, thelower plate-like body portion 548 of the lower coupling member 546comprises a pair of spaced-apart fastener apertures 552 disposed thereinfor receiving respective fasteners 264 (see FIG. 150). In FIG. 150, twoskirt sections 554 are illustrated being coupled together using thecoupling member 546.

Alternative embodiments of the clamp members are depicted in FIGS.151-156. Initially, with reference to FIG. 151, a clamp assembly thatincludes the upper clamp member 402 described above and the lower clampmember 558 is being used to secure a skirt member 556 and a photovoltaicmodule 372 in place. Turning to FIGS. 152 and 153, it can be seen thatthe lower clamp member 558 comprises a base portion 568 with upturnedside edges, and first and second vertical walls 560, 562 extendingupwardly from the base portion 568. The base portion 568 of the lowerclamp member 558 further comprises a fastener aperture 570 for receivinga fastener member (e.g., bolt 264 depicted in FIG. 151). In addition, asshown in FIGS. 152 and 153, the lower clamp member 558 comprises a pairof spaced-apart skirt receiving notches 564, 566 for receiving aprotruding portion of a skirt member 556 (see FIG. 151). Next, referringto FIGS. 154 and 155, a lower clamp member 572 is illustrated thatcomprises a lower plate-like body portion 574 and a curled upper bodyportion 576 for engaging one or more skirt members. Also, as shown inFIG. 154, the lower plate-like body portion 574 of the lower clampmember 572 comprises a fastener aperture 578 disposed therein forreceiving a fastener (e.g., bolt 264 depicted in FIG. 156). In FIG. 156,a skirt member 580 is illustrated being secured to a support surfaceattachment device by means of the lower clamp member 572. As shown inFIG. 156, the support surface attachment device includes a glider member60″ and a base member 90″.

Now, with reference to FIGS. 157-159, 162-167, and 169, severalembodiments of spacer members that are used to hold open the panelreceiving gaps of the clamp assembly and the coupling assembly will bedescribed. It is to be understood that spacer members are only necessaryin the southmost row of the photovoltaic array to hold open the clampand coupling assemblies because the photovoltaic modules acts as thespacers in the other rows of the photovoltaic array. Initially,referring to FIG. 157, it can be seen that plate-like spacer member 590may be inserted between the lower clamp member 414′ and the skirt member582 in order to hold open the clamp assembly and support the skirtmember 582 (e.g., during the setting of the sourthmost row in aphotovoltaic array so as to prevent the north side of the clamp fromclosing out). As shown in FIG. 158, the spacer member 590 comprises aplate-like body portion 592 with a rounded upper corner 594 toaccommodate the channel portion of the skirt member 582 that defines thegroove 586. In FIG. 159, it can be seen that the skirt member 582comprises a body portion 584 with a hemmed upper edge portion 588 and agroove 586 for receiving the protruding teeth of the upper clamp member402 (see FIG. 157). As shown in FIG. 157, the hemmed upper edge portion588 of the skirt member 582 fits within a recess of the upper clampmember 402 so that, together with the engagement between the groove 586and the protruding teeth of the upper clamp member 402, the skirt member582 is secured in place on the clamp assembly.

Another embodiment of a spacer member will be described with referenceto FIGS. 162 and 163. As shown in these figures, the spacer member 602has a generally C-shaped body portion 604 with oppositely disposedpronged end portions 606. The spacer member 602 of FIGS. 162 and 163 isdesigned to clip onto the lower clamp member of the clamp assembly(i.e., the pronged end portions 606 of the spacer member 602 clips ontothe lower clamp member). Yet another embodiment of a spacer member isdepicted in FIG. 169. As shown in FIG. 169, the spacer member 608 has asemi-circular body portion with a centrally disposed fastener aperture610 for accommodating a shaft of a fastener member. As shown in FIGS.164-167, the spacer member 608 is designed to snap into place on theshaft of the clamp fastener member 38 and on the shafts of the couplingfastener members 168 so as to hold the clamp and the coupling assembliesopen.

An illustrative embodiment of yet another clamp assembly is seengenerally at 782 in FIGS. 171 and 172. In one or more embodiments, theclamp assembly 782 is provided as part of a support surface attachmentdevice that is used to attach one or more photovoltaic modules to asupport surface (e.g., a sloped building roof). In addition to the clampassembly 782 illustrated in FIGS. 171 and 172, the support surfaceattachment device of the illustrative embodiment additionally comprisesa base assembly that includes a base member, a flashing member, and athreaded fastener member. The base assembly of the support surfaceattachment device is described in detail above in the precedingembodiments (e.g., base assemblies 128, 128′ described above).

Initially, with reference to FIGS. 171 and 172, it can be seen that theillustrative embodiment of the clamp assembly 782 generally includes anupper clamp member 710, a lower clamp member 720, and a glider member760. As best shown in the assembled view of FIG. 171, the upper clampmember 710, lower clamp member 720, and glider member 760 are connectedto one another by means of a threaded fastener member 738 and a strutnut 772. In the illustrated embodiment, the threaded fastener member 738is in the form of a bolt with a head portion having a serrated flange740 (refer to FIG. 173). The serrations in the lower surface of the bolthead flange of the threaded fastener member 738 are configured tointerferingly engage with the top surface of the upper clamp member 710(i.e., “dig into” the top surface of the upper clamp member 710). Theexternal threads on the shaft of the threaded fastener member 738 areconfigured to threadingly engage with the internal threads 774 in themiddle of the strut nut 772 (see FIG. 183). Also, as shown in FIG. 173,the top surface of the head portion of the threaded fastener member 738is provided with a visual indicator line 741 formed therein forindicating the orientation of the strut nut 772 that is threadinglyengaged with the threaded fastener member 738. As shown in FIG. 183, thestrut nut 772 has spaced-apart elongate grooves 776 disposed in the topsurface thereof that are each configured to receive a respectivedownturned lip of a base member (e.g., the downturned lip 108 of thebase members 90, 90′ described above). In addition, as best shown in thetop perspective view of FIG. 183, it can be seen that each of theelongate grooves 776 is provided with two (2) spaced-apart protrusionsor teeth 777 disposed therein. The spaced-apart teeth 777 in each groove776 are configured to interferingly engage with a bottom surface of oneof the downturned lips of the base member (i.e., “dig into” the bottomsurface of one of the downturned lips of the base member). Also,referring again to FIG. 183, it can be seen that the strut nut 772comprises curved sidewall portions 778 arranged diagonally opposite fromone another. The curved sidewall portions 778 allow the strut nut 772 torotate clockwise into position until the flat sidewall portions contactthe inside walls of the base member.

Referring again to the illustrative embodiment of FIG. 171, it can beseen that the upper clamp member 710 and the lower clamp member 720 ofclamp assembly 782 cooperate to clamp one or more photovoltaic modulesin place on a support surface. That is, each photovoltaic module isclamped in place either between the first opposed flange portion 714 aof the upper clamp member 710 and the second outwardly extending ledge728 of the lower clamp member 720 or between the second opposed flangeportion 714 b of the upper clamp member 710 and the first outwardlyextending ledge 726 of the lower clamp member 720, depending on whichside of the clamp assembly 782 the photovoltaic module is disposed.

Now, with reference to FIGS. 174 and 175, the structure of the upperclamp member 710 will be described. As shown in these figures, the upperclamp member 710 generally includes a base portion 712 that is attachedto the bottom surface of a flange portion 714 a, 714 b at approximatelya 90 degree angle. In this figure, it can be seen that one side surfaceof base portion 712 comprises a plurality of elongate protrusions orteeth 718 that are each spaced apart from one another by respective gaps719. As will be described hereinafter, a predetermined one of theplurality of elongate protrusions or teeth 718 matingly engage with apredetermined one of elongate protrusions or teeth 730 disposed on thefirst opposed wall portion 724 a of the upstanding middle portion 722 ofthe lower clamp member 720. Referring again to FIG. 175, it can be seenthat the flange portion 714 a, 714 b of the upper clamp member 710further comprises a fastener aperture 715 for receiving the threadedfastener member 738 and a downwardly protruding member 717 that forms aback surface against which a photovoltaic module rests when disposed inthe clamp assembly 782. Also, as shown in FIGS. 174 and 175, each of theflange portions 714 a, 714 b includes an elongate groove 716 disposed inthe bottom surface thereof. Each of the elongate grooves 716 isconfigured to receive first and second tab portions 747, 748 of arespective bonding clip 742 (see FIG. 176) that provides integratedgrounding for the photovoltaic module installation. The first and secondtab portions 747, 748 of each bonding clip 742 are received within theelongate groove 716 in a press-fit or interference-fit type mountingarrangement.

Referring again to FIGS. 174 and 175, it can be seen that the flangeportion 714 b of the upper clamp member 710 further comprises an angledlower surface 713. As described hereinafter, the angled lower surface713 of the flange portion 714 b is configured to interact with thespring member 750 as so to displace the vertical base portion 712 andthe plurality of first teeth 718 outwardly away from the plurality ofsecond teeth 730 on the lower clamp member 720 when the fastener member738 is being tightened until the desired module thickness setting pullsthe upper clamp member 710 into the lower clamp member 720. Also, asshown in FIGS. 174 and 175, the downwardly protruding member 717 of theupper clamp member 710 comprises a groove 711 formed in one side thereoffor capturing an edge of the bonding clip 742, and holding it in place(refer to FIGS. 191 and 192).

The bonding or grounding clip 742, which provides integrated groundingfor the photovoltaic modules, is illustrated in FIG. 176. The bondingclip 742 generally comprises a plate-like body portion 743 with anupturned flange 745 attached to the one side of the plate-like bodyportion 743. As shown in FIG. 176, the upturned flange 745 of thebonding clip 742 comprises a pair of spaced-apart bent over tab portions747, 748, wherein each tab 747, 748 is disposed at an opposite end ofthe upturned flange 745. In FIG. 176, it can be seen that the plate-likebody portion 743 includes a plurality of upwardly protruding annularmembers 744 and a plurality of downwardly protruding annular members746. In particular, in the illustrative embodiment, the upwardly anddownwardly protruding annular members 744, 746 are arranged in astaggered, alternating sequence (i.e., a first upwardly protrudingannular member 744 followed by an offset downwardly protruding annularmember 746, then followed by an offset second downwardly protrudingannular member 746, and finally, an offset second upwardly protrudingannular member 744). The upwardly protruding members 744 are designed topierce the metallic bottom surface of the flange portion 714 a, 714 b ofthe upper clamp member 710, while the downwardly protruding annularmembers 746 are designed to pierce the anodized layer of thephotovoltaic module to provide integrated grounding between thephotovoltaic modules. To facilitate integrated grounding between thephotovoltaic modules, all of the components of the clamp assembly 782 ofthe support surface attachment device, and the coupling device 788described hereinafter, may be formed from metal.

Next, turning to FIGS. 178 and 179, the structure of the lower clampmember 720 will be explained. With reference to these figures, it can beseen that the lower clamp member 720 generally includes an upstandingmiddle portion 722 with first and second ledge portions 726, 728extending outwardly from the upstanding middle portion 722. In FIG. 179,it can be seen that the upstanding middle portion 722 of the lower clampmember 720 comprises an upper fastener aperture 725 disposed in a topwall portion 723 thereof. The upstanding middle portion 722 of the lowerclamp member 720 similarly comprises a lower fastener aperture disposedin a bottom wall portion thereof. Each of these apertures receives theshaft of the threaded fastener member 738. As shown in FIGS. 178 and179, the bottom wall portion and the top wall portion 723 of theupstanding middle portion 722 of the lower clamp member 720 areconnected to one another by first and second opposed wall portions 724a, 724 b. Also, as illustrated in FIGS. 178 and 179, the first opposedwall portion 724 a comprises a plurality of elongate protrusions orteeth 730 that are each spaced apart from one another by respective gaps732. As explained above, a predetermined one of the elongate teeth 730of the first opposed wall portion 724 a engages with a predetermined oneof the elongate teeth 718 of the base portion 712 of the upper clampmember 710. Referring again to FIG. 179, it can be seen that, unlike thefirst opposed wall portion 724 a, the second opposed wall portion 724 bcontains no teeth thereon. Between the rows of the photovoltaic array,each of the first and second ledge portions 726, 728 of the lower clampmember 720 is configured to accommodate a photovoltaic module framemember resting thereon. As described herein, on the south edge of thephotovoltaic array, the first ledge portion 726 of the lower clampmember 720 is configured to accommodate a skirt member 826 and a skirtspacer member, while the second ledge portion 728 of the lower clampmember 720 is configured to accommodate a photovoltaic module framemember resting thereon.

With reference to FIGS. 178 and 179, it can be seen that the secondopposed ledge 728 of the lower clamp member 720 is bent slightly upwardor is tapered slightly upward at an acute angle. In the installed state,the upwardly tapered ledge 728 of the lower clamp member 720 extendsuphill and slightly up and away from the building roof so as to act as aleaf spring that takes up the difference in gap between the uphill clampopening and the photovoltaic (PV) module thickness, thereby preventingthe PV module from rattling and allowing it to be secured into place. Insome embodiments, this also creates enough pressure on the upper clamplip (i.e., first opposed flange portion 714 a of upper clamp member 710)to enable a bonding point to function. Advantageously, because thesecond opposed ledge 728 of the lower clamp member 720 is provided witha slight upward taper (i.e., bowed upwardly), the lower clamp member 720applies a compressive force against the PV module when it is installedtherein. During the installation of each PV module, the PV module isinitially disposed at an upward acute angle relative to its one or moresouthern clamp assemblies 782. Then, each PV module is rotated downuntil it is generally parallel with the roof surface. As each PV moduleis rotated downwardly towards the roof surface, the edge portion of theuphill PV module presses down on the upwardly tapered ledge(s) 728 ofthe lower clamp member(s) 720 so as to apply a downward force on theupwardly tapered ledge 728, thereby ensuring that the PV module issecurely engaged with the lower clamp member(s) 720 and the PV module istightly held in place. In response to the downward force applied by thePV module, the upwardly tapered ledge 728 elastically deforms or yieldsin a spring-like manner. As a result of the leaf spring design of theupwardly tapered ledge 728, the installer is not required to reach downover the PV module to tighten the fasteners on its one or more southernclamp assemblies 782. An attempt by the installer to tighten thefasteners on the one or more southern clamp assemblies 782 would not besafe, ergonomic, or efficient. The second ledge portion 808 of the lowercoupling member 800 described hereinafter may be bent slightly upward ortapered slightly upward at an acute angle in the same manner as thatdescribed above for the upwardly tapered ledge 728 of the lower clampmember 720 so that the coupling device 788 is provided with the samefunctionality that is described above for the clamp assembly 782. Asshown in FIGS. 178 and 179, the upwardly tapered ledge 728 comprises anend portion of reduced thickness so as to accommodate a wire retainingclip fastened thereto.

Referring again to FIGS. 178 and 179, it can be seen that the upwardlytapered ledge 728 of the lower clamp member 720 further comprises awater drainage trough 734 formed therein for draining water from the oneor more photovoltaic modules (i.e., the water drainage trough 734provides water drainage on the uphill side of the clamp assembly 782 sothat the clamp does not impede module drain holes, and the water isallowed to drain from module flanges). Also, as shown in FIGS. 178 and179, the shorter ledge 726 of the lower clamp member 720 comprises anelongate groove 735 formed therein for engaging with a mating protrusion842, 850, 858 of a skirt spacer member 836, 844, 852 (see FIGS.195-200). In the illustrative embodiment, the groove 735 is in the formof a dovetail groove to retain the skirt spacer member 836, 844, 852,and the dovetail protrusion 842, 850, 858 of the skirt spacer member836, 844, 852 slides into the groove 735 from the side of the lowerclamp member 720. Referring again to FIGS. 178 and 179, it can be seenthat the shorter ledge 726 of the lower clamp member 720 furthercomprises a plurality of serrations 736 for securely gripping the one ormore photovoltaic modules and for providing airflow and water drainageon the downhill side of the clamp assembly 782. In addition, as shown inthe perspective view of FIG. 179, the shorter ledge 726 of the lowerclamp member 720 further comprises a retaining element 737 formedthereon for retaining the skirt spacer member 836, 844, 852 in place onthe ledge 726 of the lower clamp member 720 after the mating protrusion842, 850, 858 of the skirt spacer member 836, 844, 852 is engaged withthe groove 735 in the ledge 726 (i.e., the retaining element 737provides resistance once the skirt spacer member 836, 844, 852 slidesinto the dovetail groove 735 to retain it).

Further, as also shown in FIGS. 178 and 179, the lower clamp member 720of the clamp assembly 782 comprises a plurality of ridges 727 disposedon a bottom surface thereof. The ridges 727 are configured to increase africtional engagement between the lower clamp member 720 and the glidermember 760 so as prevent the upper and lower clamp members 710, 720 ofthe clamp assembly 782 from rotating relative to the glider member 760when the threaded fastener member 738 is tightened by an installer(i.e., the ridges 727 increase the resistance to rotation of the clampassembly on the glider member 760).

In the illustrative embodiment described herein, the clamp assembly 782relies on a single tooth design to set the clamp height and allow forphotovoltaic module insertion from the uphill side (i.e., north side).Advantageously, the clamp assembly 782 does not require additionaltightening after the uphill photovoltaic module is inserted. Thealternating tooth interaction 718, 730 between the upper clamp member710 and the lower clamp member 720 provides settings for the followingmodule thicknesses: 32 millimeters (mm), 33 millimeters (mm), 35millimeters (mm), 38 millimeters (mm), 40 millimeters (mm), and 46millimeters (mm). The clamp assembly 782 is universal for each of thesesettings. As such, there are no changes or additional clampconfigurations needed for these six (6) module thicknesses. As describedhereinafter, a single, universal skirt member 826 is used for all sixmodule thicknesses.

In order to maintain a predetermined spacing distance between the upperand lower clamp members 710, 720 during PV module installation, a springmember 750 is provided between the clamp members 710, 720 (refer to FIG.171). In an exemplary embodiment, the spring member 750 may be Z-shaped.That is, as best shown in FIG. 171, the spring member 750 is disposedbetween the top wall portion 723 of the lower clamp member 720 and theangled lower surface 713 of the flange portion 714 a, 714 b of the upperclamp member 710. During the installation of the PV modules in the PVarray, the spring member 750 holds the upper clamp member 710 in placeabove the lower clamp member 720 so that a PV module can be insertedbetween the two (2) clamp members 710, 720. Without the use of thespring member 750, the flange 714 a, 714 b of the upper clamp member 710would tend to just rest on the top of the lower clamp member 720,thereby making it very difficult to insert the PV module between the two(2) clamp members 710, 720. In addition, the use of the spring member750 in the clamp assembly 782 allows the fastener member 738 to betightened so that the strut nut 772 engages the base and secures theclamp to the base without the clamp being compressed.

Turning again to FIG. 177, it can be seen that the spring member 750 ofthe clamp assembly 782 comprises bottom and top leg portions 752, 756,which are connected to one another by a middle diagonal leg portion 754.Each of the leg portions 752, 754, 756 is provided with a respectiveoval-shaped fastener aperture 758 disposed therethrough foraccommodating the shaft of the threaded fastener member 738.

As best shown in FIG. 171, the lower clamp member 720 is positionedabove a glider member 760 that is configured to be adjustably disposedon an upstanding base member 90, 90′ in both a horizontal and verticaldirection (as explained above in the preceding embodiments). Referringto FIGS. 180 and 181, it can be seen that the glider member 760 of theclamp assembly 782 comprises a generally inverted, U-shaped profile witha top wall portion 764 and first and second opposed wall portions 766 a,766 b extending downwardly from the top wall portion 764. The top wallportion 764 comprises a fastener aperture 762 disposed centrally thereinfor receiving the shaft of the threaded fastener member 738. In FIGS.180 and 181, it can be seen that the inner surfaces of each of the firstand second opposed wall portions 766 a, 766 b comprises a plurality ofelongate protrusions or teeth 768 that are each spaced apart from oneanother by respective elongate grooves 770. The set of teeth 768 on eachof the inner surfaces of the opposed wall portions 766 a, 766 b aredesigned to engage with respective teeth on opposed upstanding wallportions of the base member 90, 90′ (as described above in the precedingembodiments). The glider member 760 may be elastically deformable suchthat it is capable of snapping into place on the top of the base member,or alternatively, it may simply be designed to slide into place on thebase assembly. To permit horizontal adjustability, the glider member 760is capable of being slid along the length of the base member. And, topermit vertical adjustability, the glider member 760 is capable of beingmoved up and down along a vertical height of the upstanding wallportions of the base member 90, 90′ and selectively engaging certainones of the teeth with one another.

Also, as shown in FIGS. 180 and 181, the outer sides of the first andsecond opposed wall portions 766 a, 766 b of the glider member 760 areprovided with a plurality of generally parallel, visual indicatorgrooves 761 formed therein (e.g., three (3) visual indicator grooves761). During the installation of the PV modules, the visual indicatorgrooves 761 operate as visual indicating bands for positioning the clampassembly 782 at its desired height (i.e., the visual indicator grooves761 enable the desired height of the clamp assembly 782 relative to thebase member to be more easily obtained by the installer during the PVmodule installation process). Also, referring again to FIGS. 180 and181, it can be seen that opposed protrusions 763 may be provided at thetop of the glider member 760 for holding a chalk line (e.g., a string)in place that is used for the alignment of the PV module row on thesupport surface (e.g., roof). In an illustrative embodiment, the chalkline (e.g., a string) may be received within the topmost one of thegrooves 761, and the lower two (2) grooves 761 may be used as visual aidindicators showing the height of the glider member 760 on the upstandingbase member (i.e., corresponding to the grooves 761).

With reference to FIGS. 172 and 182, it can be seen that, in theillustrative embodiment, the clamp assembly 782 is further provided withan O-ring 780 disposed between the glider member 760 and the strut nut772. The O-ring 780 stabilizes the clamp assembly on the glider member760 prior to installation.

Now, with reference to FIGS. 184-190, an illustrative embodiment of acoupling device or assembly 788 of the solar panel mounting system willbe described. Referring to these figures, it can be seen that theillustrative coupling device or assembly 788 generally includes an uppercoupling member 790 secured to a lower coupling member 800. As bestshown in the assembled view of FIG. 184 and the exploded view of FIG.185, the upper coupling member 790 and the lower coupling member 800 areconnected to one another by means of one or more threaded fastenermembers 820 (e.g., two (2) threaded fastener members 820). In theillustrated embodiment, each threaded fastener member 820 is in the formof a bolt with a head portion having a serrated flange 822 (e.g., referto FIG. 186). As described above for the bolt 738 of the clamp assembly782, the serrations in the lower surface of the bolt head flange of eachthreaded fastener member 822 are configured to interferingly engage withthe top surface of the upper coupling member 790 (i.e., “dig into” thetop surface of the upper coupling member 790). The external threads onthe shaft of each threaded fastener member 820 are configured tothreadingly engage with the internal threads of the threaded apertures805 of the lower coupling member 800 (see FIGS. 185 and 190).

Turning to FIGS. 187 and 188, the structure of the upper coupling member790 will be described. As shown in these figures, the upper couplingmember 790 generally includes a base portion 792 that is attached to thebottom surface of a flange portion 794 a, 794 b at approximately a 90degree angle. In this figure, it can be seen that one side surface ofbase portion 792 comprises a plurality of elongate protrusions or teeth798 that are each spaced apart from one another by respective gaps 799.As will be described hereinafter, a predetermined one of the pluralityof elongate protrusions or teeth 798 matingly engages with apredetermined one of the elongate protrusions or teeth 810 disposed onthe first opposed wall portion 804 a of the upstanding middle portion802 of the lower coupling member 800. Referring again to the perspectiveview of FIG. 188, it can be seen that the flange portion 794 a, 794 b ofthe upper coupling member 790 further comprises a plurality of fastenerapertures 793, 795 for receiving respective threaded fastener members820 and a downwardly protruding member 797 that forms a back surfaceagainst which a photovoltaic module rests when disposed in the couplingassembly 788. In the illustrative embodiment of FIG. 188, it can be seenthat each of fastener apertures 793 has a generally oval shape, whilethe fastener aperture 795 has a generally circular shape. Also, as shownin FIGS. 187 and 188, each of the flange portions 794 a, 794 b includesan elongate groove 796 disposed in the bottom surface thereof. Each ofthe elongate grooves 796 is configured to receive first and second tabportions 747, 748 of a respective bonding clip 742 (see FIG. 176) thatprovides integrated grounding for the photovoltaic module installation.The first and second tab portions 747, 748 of each bonding clip 742 arereceived within the elongate groove 796 in a press-fit orinterference-fit type mounting arrangement.

Referring again to FIGS. 187 and 188, it can be seen that the flangeportion 794 b of the upper coupling member 790 further comprises anangled lower surface 791. The angled lower surface 791 of the flangeportion 794 b is substantially equivalent to the angled lower surface713 of the flange 714 b of the upper clamp member 710 described above soas to allow the same extrusion profile to be used for both the uppercoupling member 790 and the upper clamp member 710. Also, as shown inFIGS. 187 and 188, similar to the upper clamp member 710 describedabove, the downwardly protruding member 997 of the upper coupling member790 comprises a groove or notch formed in the outer side thereof forcapturing an edge of the bonding clip 742, and holding it in place.

Next, turning to FIGS. 189 and 190, the structure of the lower couplingmember 800 will be explained. With reference to these figures, it can beseen that the lower coupling member 800 generally includes an upstandingmiddle portion 802 with first and second ledge portions 806, 808extending outwardly from the upstanding middle portion 802. In theperspective view of FIG. 190, it can be seen that the upstanding middleportion 802 of the lower coupling member 800 comprises spaced-apartthreaded fastener apertures 805 disposed in a top wall portion 803thereof. Each of these apertures 805 is configured to threadinglyreceive a respective shaft of a respective threaded fastener member 820.The bottom wall portion and the top wall portion 803 of the upstandingmiddle portion 802 of the lower coupling member 800 are connected to oneanother by first and second opposed wall portions 804 a, 804 b. As shownin FIGS. 189 and 190, the first opposed wall portion 804 a comprises aplurality of elongate protrusions or teeth 810 that are each spacedapart from one another by respective gaps 812. As explained above, apredetermined one of the elongate teeth 810 of the first opposed wallportion 804 a engages with a predetermined one of the elongate teeth 798of the base portion 792 of the upper coupling member 790. Referringagain to FIGS. 189 and 190, it can be seen that, unlike the firstopposed wall portion 804 a, the second opposed wall portion 804 bcontains no teeth thereon. Between the rows of the photovoltaic array,each of the first and second ledge portions 806, 808 of the lowercoupling member 800 is configured to accommodate a photovoltaic moduleframe member resting thereon. As described herein, on the south edge ofthe photovoltaic array, the first ledge portion 806 of the lowercoupling member 800 is configured to accommodate a skirt member 826 anda skirt spacer member, while the second ledge portion 808 of the lowercoupling member 800 is configured to accommodate a photovoltaic moduleframe member resting thereon. As shown in FIGS. 189 and 190, similar tothe upwardly tapered clamp ledge 728 described above, the upwardlytapered ledge 808 of the lower coupling member 800 comprises an endportion of reduced thickness so as to accommodate a wire retaining clipfastened thereto.

Referring again to FIGS. 189 and 190, it can be seen that the upwardlytapered ledge 808 of the lower coupling member 800 further comprises awater drainage trough 807 formed therein for draining water from the oneor more photovoltaic modules (i.e., the water drainage trough 807provides water drainage on the uphill side of the coupling assembly 788so that the coupling does not impede module drain holes, and the wateris allowed to drain from module flanges). Also, as shown in FIGS. 189and 190, the shorter ledge 806 of the lower coupling member 800comprises an elongate groove 814 formed therein for engaging with amating protrusion 842, 850, 858 of a skirt spacer member 836, 844, 852(see FIGS. 195-200). In the illustrative embodiment, the groove 814 isin the form of a dovetail groove to retain the skirt spacer member 836,844, 852, and the dovetail protrusion 842, 850, 858 of the skirt spacermember 836, 844, 852 slides into the groove 814 from the side of thelower coupling member 800. Referring again to FIGS. 189 and 190, it canbe seen that the shorter ledge 806 of the lower coupling member 800further comprises a plurality of serrations 816 for securely grippingthe one or more photovoltaic modules and for providing airflow and waterdrainage on the downhill side of the coupling assembly 788. In addition,as shown in the perspective view of FIG. 190, the shorter ledge 806 ofthe lower coupling member 800 further comprises a pair of retainingelements 818 formed thereon for retaining respective skirt spacermembers 836, 844, 852 in place on the ledge 806 of the lower couplingmember 800 after the mating protrusions 842, 850, 858 of the respectiveskirt spacer members 836, 844, 852 are engaged with the groove 814 inthe ledge 806 (i.e., the retaining elements 818 provide resistance oncethe skirt spacer members 836, 844, 852 slide into dovetail groove 814 toretain them).

With reference to the exploded view of FIG. 185, it can be seen that, inthe illustrative embodiment, the coupling assembly 788 is furtherprovided with an O-ring 824 disposed between the upper coupling member790 and the lower coupling member 800. The O-ring 824 helps to hold openthe coupling assembly 788 prior to installation.

In the illustrative embodiment described herein, the coupling assembly788 relies on a single tooth design to set the coupling height and allowfor photovoltaic module insertion from the uphill side (i.e., northside). Advantageously, the coupling assembly 788 does not requireadditional tightening after the uphill photovoltaic module is inserted.The alternating tooth interaction 798, 810 between the upper couplingmember 790 and the lower coupling member 800 provides settings for thefollowing module thicknesses: 32 millimeters (mm), 33 millimeters (mm),35 millimeters (mm), 38 millimeters (mm), 40 millimeters (mm), and 46millimeters (mm). The coupling assembly 788 is universal for each ofthese settings. As such, there are no changes or additional couplingconfigurations needed for these six (6) module thicknesses. As describedhereinafter, a single, universal skirt member 826 is used for all sixmodule thicknesses.

With reference to FIGS. 191-194, a skirt member 826 of the photovoltaicmounting system will be described. In a roof-mounted installation, theskirt member 826 is configured to be located on the southernmost edge ofthe array of PV modules. The skirt member 826 is supported byspaced-apart support surface attachment devices. In particular, as shownin the end views of FIGS. 191 and 192, the skirt member 826 engages withthe upper clamp member 710 and the lower clamp member 720 of the clampassembly 782 of the support surface attachment device. As shown in thesefigures, the skirt member 826 is clampingly engaged between by the upperand lower clamp members 710, 720. Advantageously, the skirt member 826is universal for all six module thicknesses described above (i.e., theinstaller can use same skirt for all modules).

With reference to FIGS. 193 and 194, the structure of the skirt member826 of the illustrative embodiment will be described. As shown in thesefigures, the skirt member 826 has a skirt body that generally includesan angled wall portion 828 and an upper end portion 830. A notch 834 isformed in the top surface of the upper end portion 830 of the skirtmember 826 for receiving the downwardly extending lip portion of theflange portion 714 b of the upper clamp member 710 (see FIGS. 191 and192) to more securely retain the skirt member 826 in place within theclamp assembly 782. Also, as shown in FIGS. 193 and 194, the skirtmember 826 comprises a vertical skirt leg 832 extending downwardly fromthe upper end portion 830 thereof. The vertical skirt leg 832 retainsthe skirt member 826 between the skirt spacer member 836, 852 and thelower clamp member 720 during the installation of the skirt member 826until the skirt member 826 is secured in the clamp assembly 782 betweenthe upper and lower clamp members 710, 720 (refer to FIGS. 191 and 192).The vertical skirt leg 832 advantageously acts as an installation aid.The skirt member 826 is held lightly in place during installation untilthe skirt member 826 is able to be clamped down in the clamp assembly782 and the coupling assembly 788.

Now, the skirt spacer members of the solar panel mounting system will bedescribed with reference to FIGS. 191, 192, and 195-200. In theillustrative embodiment, there are six (6) skirt spacer sizes (i.e., onefor each individual module thickness). As such, in the illustrativeembodiment, there are separate spacer members for each of the followingphotovoltaic module thicknesses: 32 millimeters (mm), 33 millimeters(mm), 35 millimeters (mm), 38 millimeters (mm), 40 millimeters (mm), and46 millimeters (mm). For example, a skirt spacer member 836 configuredfor a 46 millimeter module thickness is illustrated in FIGS. 195 and196. As shown in these figures, the 46 mm skirt spacer member 836comprises an angled notch 838 configured to receive the distal end ofthe vertical skirt leg 832 of the skirt member 826 during installation(refer to FIG. 192). Also, as shown in FIGS. 195 and 196, the 46 mmskirt spacer member 836 comprises indicia or identification markings 840denoting the spacer size (i.e., the six (6) lines engraved in the topsurface of the spacer body portion indicate that the skirt spacer member836 is for a 46 millimeter module thickness). Referring again to FIGS.195 and 196, it can be seen that the 46 mm skirt spacer member 836further comprises a mating protrusion 842 configured to be inserted intothe groove 735 of the lower clamp member 720 or the groove 814 of thelower coupling member 800. In the illustrative embodiment, the matingprotrusion 842 of the skirt spacer member 836 is in the form of adovetail protrusion that is configured to be received within thedovetail groove 735 of the lower clamp member 720 or the dovetail groove814 of the lower coupling member 800 in the manner described above.

As another example, a skirt spacer member 844 configured for a 38millimeter module thickness is illustrated in FIGS. 197 and 198. Asshown in these figures, the 38 mm skirt spacer member 844 comprises anangled notch 846 configured to receive the distal end of the verticalskirt leg 832 of the skirt member 826 during installation (similar tothat shown in FIGS. 191 and 192). Also, as shown in FIGS. 197 and 198,the 38 mm skirt spacer member 844 comprises indicia or identificationmarkings 848 denoting the spacer size (i.e., the four (4) lines engravedin the top surface of the spacer body portion indicate that the skirtspacer member 844 is for a 38 millimeter module thickness). Referringagain to FIGS. 197 and 198, it can be seen that the 38 mm skirt spacermember 844 further comprises a mating protrusion 850 configured to beinserted into the groove 735 of the lower clamp member 720 or the groove814 of the lower coupling member 800. In the illustrative embodiment,the mating protrusion 850 of the skirt spacer member 844 is in the formof a dovetail protrusion that is configured to be received within thedovetail groove 735 of the lower clamp member 720 or the dovetail groove814 of the lower coupling member 800 in the manner described above.

As yet another example, a skirt spacer member 852 configured for a 32millimeter module thickness is illustrated in FIGS. 199 and 200. Asshown in these figures, the 32 mm skirt spacer member 852 comprises anangled notch 854 configured to receive the distal end of the verticalskirt leg 832 of the skirt member 826 during installation (refer to FIG.191). Also, as shown in FIGS. 199 and 200, the 32 mm skirt spacer member852 comprises indicia or identification markings 856 denoting the spacersize (i.e., the one (1) line engraved in the top surface of the spacerbody portion indicates that the skirt spacer member 852 is for a 32millimeter module thickness). Referring again to FIGS. 199 and 200, itcan be seen that the 32 mm skirt spacer member 852 further comprises amating protrusion 858 configured to be inserted into the groove 735 ofthe lower clamp member 720 or the groove 814 of the lower couplingmember 800. In the illustrative embodiment, the mating protrusion 858 ofthe skirt spacer member 852 is in the form of a dovetail protrusion thatis configured to be received within the dovetail groove 735 of the lowerclamp member 720 or the dovetail groove 814 of the lower coupling member800 in the manner described above.

While the skirt spacer members for 33 mm, 35 mm, and 40 mm photovoltaicmodule thicknesses are not explicitly shown in the drawings, it is to beunderstood that, in the illustrative embodiment, these skirt spacermembers contain the same features as the 32 mm, 38 mm, and 46 mm spacermembers described above, but have different heights to accommodate theirassociated module thicknesses. That is, like the 32 mm, 38 mm, and 46 mmspacer members, the 33 mm, 35 mm, and 40 mm spacer members also eachinclude an angled notch for receiving the distal end of the verticalskirt leg 832 of the skirt member 826, indicia or identificationmarkings denoting the spacer size, and a mating protrusion configured tobe inserted into the groove 735 of the lower clamp member 720 or thegroove 814 of the lower coupling member 800. Also, like the 32 mm, 38mm, and 46 mm spacer members described above, the 33 mm, 35 mm, and 40mm spacer members are each configured to be disposed between an upperend portion 830 of the skirt member 826 and the ledge 726 of the lowerclamp member 720 or the ledge 806 of the lower coupling member 800 so asto elevate the skirt member 826 above a top surface of the ledge 726 ofthe lower clamp member 720 or the ledge 806 of the lower coupling member800.

In the illustrative embodiment, the skirt spacer members are used onlyon the south row of the photovoltaic array, and are used to set theclamp and coupling opening widths to the proper module thickness. Forthe photovoltaic array to be properly installed, the skirt spacer membercorresponding to the correct module thickness needs to be used by theinstaller. In the illustrative embodiment, only one spacer is used perclamp assembly 782, while two spacers are used per coupling assembly788.

Any of the features or attributes of the above described embodiments andvariations can be used in combination with any of the other features andattributes of the above described embodiments and variations as desired.

Although the invention has been shown and described with respect to acertain embodiment or embodiments, it is apparent that this inventioncan be embodied in many different forms and that many othermodifications and variations are possible without departing from thespirit and scope of this invention.

Moreover, while exemplary embodiments have been described herein, one ofordinary skill in the art will readily appreciate that the exemplaryembodiments set forth above are merely illustrative in nature and shouldnot be construed as to limit the claims in any manner. Rather, the scopeof the invention is defined only by the appended claims and theirequivalents, and not, by the preceding description.

The invention claimed is:
 1. A mounting system for supporting aplurality of photovoltaic modules on a support surface, said mountingsystem comprising: a support surface attachment device, said supportsurface attachment device configured to attach one or more photovoltaicmodules to a support surface, said support surface attachment deviceincluding a clamp assembly, said clamp assembly including a lower clampmember and an upper clamp member, said lower clamp member having anoutwardly extending component extending from an outer side of said lowerclamp member; a skirt member, said skirt member configured to besupported by said clamp assembly; and a skirt spacer member, said skirtspacer member configured to be disposed between a portion of said skirtmember and said outwardly extending component of said lower clamp memberso as to elevate said skirt member above a top surface of said outwardlyextending component, said skirt member configured to be interchangeablyused with a plurality of different photovoltaic module thicknessesranging from 32 millimeters to 40 millimeters; wherein said skirt spacermember is one of a plurality of skirt spacer members having differentsizes, respective ones of said plurality of skirt spacer members beingsized to accommodate photovoltaic modules having the following modulethicknesses: 32 millimeters, 35 millimeters, 38 millimeters, and 40millimeters; and wherein each of said plurality of skirt spacer memberscomprises indicia for indicating that the respective skirt spacer memberis for a particular one of said module thicknesses.
 2. The mountingsystem according to claim 1, wherein said skirt member comprises avertical skirt leg extending downwardly from an upper end portion ofsaid skirt member, said vertical skirt leg configured to retain saidskirt member between said skirt spacer member and said lower clampmember during the installation of said skirt member until said skirtmember is secured in said clamp assembly between said upper and lowerclamp members.
 3. The mounting system according to claim 1, wherein saidoutwardly extending component of said lower clamp member comprises agroove formed therein for engaging with a mating protrusion of saidskirt spacer member, said engagement between said mating protrusion ofsaid skirt spacer member and said groove of said lower clamp memberconfigured to secure said skirt spacer member in place on said lowerclamp member.
 4. The mounting system according to claim 1, furthercomprising a module coupling device, said module coupling deviceconfigured to attach one or more photovoltaic modules to one or moreother photovoltaic modules; and said mounting system further comprises apair of skirt spacer members configured to be disposed between a portionof said skirt member and an outwardly extending ledge of said modulecoupling device so as to elevate said skirt member above a top surfaceof said outwardly extending ledge.
 5. A mounting system for supporting aplurality of photovoltaic modules on a support surface, said mountingsystem comprising: a support surface attachment device, said supportsurface attachment device configured to attach one or more photovoltaicmodules to a support surface, said support surface attachment deviceincluding a clamp assembly, said clamp assembly including a lower clampmember and an upper clamp member, said lower clamp member having anoutwardly extending component extending from an outer side of said lowerclamp member; a skirt member, said skirt member configured to besupported by said clamp assembly, and said skirt member comprising aprotrusion extending downwardly from an upper end portion of said skirtmember; and a skirt spacer member, said skirt spacer member configuredto be disposed between a portion of said skirt member and said outwardlyextending component of said lower clamp member so as to elevate saidskirt member above a top surface of said outwardly extending component,said skirt member configured to be interchangeably used with a pluralityof different photovoltaic module thicknesses ranging from 32 millimetersto 40 millimeters, said skirt spacer member comprising a hollow spacerbody portion that includes an internal cavity bounded on four sides, andsaid skirt spacer member comprising an upwardly facing notch configuredto receive said protrusion of said skirt member.
 6. The mounting systemaccording to claim 5, wherein said skirt spacer member is one of aplurality of skirt spacer members having different sizes, respectiveones of said plurality of skirt spacer members being sized toaccommodate photovoltaic modules having the following modulethicknesses: 32 millimeters, 35 millimeters, 38 millimeters, and 40millimeters.